KTM 1190 RC8 R Track EU 2012 Sport Bike Owner Manual

KTM 1190 RC8 R Track EU 2012 Sport Bike Owner Manual

OWNER'S MANUAL

2012 1190 RC8 R TRACK

Art. no. 3211798en

DEAR KTM CUSTOMER

DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Please enter the serial numbers of your vehicle below.

Vehicle identification number/type label ( p. 9)

Dealer's stamp

1

Engine number ( p. 9)

The owner's manual contained the latest information for this model at the time of going to print. However, it is never possible to exclude small deviations arising from further development in design and construction.

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

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

TABLE OF CONTENTS

TABLE OF CONTENTS

MEANS OF REPRESENTATION ............................................ 4

IMPORTANT INFORMATION ................................................ 5

VIEW OF VEHICLE............................................................... 7 View of vehicle, front left side........................................... 7

View of vehicle, rear right side .......................................... 8

SERIAL NUMBERS.............................................................. 9 Vehicle identification number/type label ............................ 9 Engine number................................................................ 9 Fork part number............................................................. 9 Shock absorber part number............................................. 9 Steering damper part number ........................................... 9

CONTROLS ....................................................................... 10 Clutch lever .................................................................. 10 Hand brake lever ........................................................... 10 Throttle grip.................................................................. 10 Emergency OFF switch................................................... 10 Electric starter button .................................................... 10

Quick shifter switch ....................................................... 11 Combination instrument - overview.................................. 11 Combination instrument - function buttons on handlebar ..................................................................... 11

Combination instrument - activation and test ................... 12 Display ......................................................................... 12

Info display................................................................... 13 Indicator lamps ............................................................. 13 Notes/warnings on the combination instrument................. 13

Combination instrument - ROAD mode overview ............... 15 Odometer menu, ODO/Trip 1 .......................................... 15

Odometer menu, ODO/Trip 2 .......................................... 16 FUELDISTANCE menu................................................... 16

Next service menu, DISTANCE TO Next Service................ 17

Combination instrument - RACE mode overview................ 18 Remaining laps menu, LAPSTOGO .................................. 18

Maximum lap speed menu, TOPSPEED ........................... 19 LAP/BESTLAP/LastLap menu.......................................... 19

Maximum speed menu, LAP/BESTLAP/TopSpeed ............. 20 Total distance in Race mode menu, RACEODO................. 20

Combination instrument - SET ‑ UP mode.......................... 21 SET ‑ UP menu ............................................................... 21

Mode menu, CHANGE MODE ......................................... 22 Time menu, SET CLOCK ................................................ 22

SETTINGS menu ........................................................... 23 Shift warning lamp menu, SHIFT RPMS .......................... 23

LAP button blank time, LAP BLANK TIME menu .............. 24 Number of laps menu, SET NUM LAPS ........................... 24

Fuel reserve display menu, TRIP F RESET ....................... 25 UNITS menu................................................................. 25

Kilometers/miles menu, SET KM/MILES .......................... 26 Temperature display menu, SET °C/°F ............................. 26

Additional functions menu, OPTIONS.............................. 27 Tire pressure monitor menu, TPMS ................................. 27

External temperature display menu, OPTION OUTTEMP.... 28

Displaying lap times ...................................................... 31 Displaying maximum speed ............................................ 31 Setting ROAD or RACE mode.......................................... 31 Setting the clock with SET CLOCK .................................. 31

Adjusting the shift speed RPM1/2................................... 32 Setting the blank time of the LAP button LAP BLANK TIME ......................................................... 32

Setting the number of laps SET NUM LAPS ..................... 33 Setting the kilometers/miles SET KM/MILES .................... 33

Setting the temperature unit SET °C/°F ........................... 34 Hiding the external temperature display........................... 34

Opening the filler cap .................................................... 35 Closing the filler cap...................................................... 35 Shift lever..................................................................... 35

Foot brake lever............................................................. 36

PREPARING FOR USE....................................................... 37 Advice on first use......................................................... 37

Running the engine in.................................................... 38

RIDING INSTRUCTIONS .................................................... 39 Checks and maintenance measures when preparing for use .............................................................................. 39 Starting ........................................................................ 39

Refueling...................................................................... 40

SERVICE SCHEDULE......................................................... 41 Service schedule ........................................................... 41

TUNING THE CHASSIS...................................................... 43 Adjusting the compression damping of the fork ................ 43 Adjusting the rebound damping of the fork....................... 43 Adjusting the spring preload of the fork ........................... 43

Compression damping of the shock absorber .................... 44 Adjusting the low-speed compression damping of the shock absorber .............................................................. 44 Adjusting the high-speed compression damping of the shock absorber .............................................................. 44

Adjusting the rebound damping of the shock absorber....... 45 Adjusting the spring preload of the shock absorber

Adjusting front vehicle level

x ...... 45

Steering damper............................................................ 46 Adjusting the steering damper ........................................ 46 Vehicle level ................................................................. 46

x ....................................... 47 Adjusting the vehicle level at the rear .............................. 47

Footrest position............................................................ 48 Adjusting the footrest position ........................................ 48

Adjusting the shift lever stub .......................................... 49 Adjusting the shift lever ................................................. 49

Adjusting the foot brake lever stub .................................. 50

Adjusting the foot brake lever ......................................... 51 Handlebar height........................................................... 51 Adjusting the handlebar height ....................................... 51

SERVICE WORK ON THE CHASSIS..................................... 53 Raising the rear of the motorcycle with lifting gear............ 53 Removing the rear of motorcycle from the lifting gear........ 53 Raising the front of the motorcycle with lifting gear .......... 53 Taking the motorcycle off of the front wheel stand ............ 53

Bleeding the fork legs .................................................... 54 Removing the seat ......................................................... 54 Fitting the seat.............................................................. 54 Removing the air filter x ............................................... 54

Installing the air filter Cleaning the air filter x ............................................... 55 x ................................................ 55

Removing the left side cover........................................... 56 Installing the left side cover ........................................... 56 Removing the right side cover ......................................... 56

Installing the right side cover.......................................... 57 Removing the exhaust cover ........................................... 57 Installing the exhaust cover ............................................ 57 Removing the fuel tank x ............................................. 57

Installing the fuel tank x .............................................. 58

Checking the fuel overflow reservoir................................. 60 Emptying the fuel overflow reservoir ................................ 60 Checking for chain dirt................................................... 60

Cleaning the chain......................................................... 61

2

TABLE OF CONTENTS

Checking the chain tension ............................................ 61

Adjusting the chain tension ............................................ 62 Checking the chain, rear sprocket and engine sprocket...... 62

Adjusting basic position of clutch lever............................ 63

Checking fluid level of hydraulic clutch ........................... 64 Correcting fluid level of hydraulic clutch.......................... 64

BRAKES ........................................................................... 65 Checking the front brake discs........................................ 65 Checking the rear brake disc........................................... 65 Adjusting the basic position of the hand brake lever.......... 65

Checking the front brake fluid level ................................. 66 Adding brake fluid of front brake

Checking the front brake linings...................................... 67 Checking the rear brake fluid level .................................. 67 Adding rear brake fluid

Removing the front wheel

x

x

x ................................ 66

.............................................. 67

Checking the rear brake linings ....................................... 68

WHEELS, TIRES ............................................................... 69 Removing the front frame sliders..................................... 69 Installing the front frame sliders ..................................... 69 .......................................... 69

Installing the front wheel

Removing the rear frame sliders...................................... 71 Installing the rear frame sliders....................................... 71 Removing the rear wheel

x

x

........................................... 70

........................................... 71

Installing the rear wheel

Checking rear hub cush drive Checking the tire condition............................................. 73

Checking the tire pressure .............................................. 74

ELECTRICAL SYSTEM ....................................................... 75 Removing the battery x

x ............................................ 72

x ..................................... 73

................................................ 75

Installing the battery x ................................................. 76 Recharging the battery x .............................................. 76

Changing the main fuse ................................................. 77

Changing the fuses of individual power consumers............ 78

COOLING SYSTEM ............................................................ 80 Cooling system .............................................................. 80 Checking the coolant level.............................................. 80 Filling cooling system compensating tank ........................ 80

Adding coolant/bleeding the cooling system

TUNING THE ENGINE ....................................................... 83 Checking the play in the throttle cable............................. 83 Adjusting the play in the throttle cable x

x ................ 81

....................... 83 Quick shifter ................................................................. 83

Checking/tuning the position of the quick shifter

Positioning the quick shifter ........................................... 86

SERVICE WORK ON THE ENGINE ...................................... 87 Checking the engine oil level .......................................... 87 Changing engine oil and filter, cleaning oil screen

x

x

......... 84

....... 87 Draining engine oil, cleaning oil screens

Removing the oil filter

x ..................... 87

x ............................................... 88

Installing the oil filter x ............................................... 89 Filling up with engine oil x ........................................... 89

Adding engine oil .......................................................... 90

CLEANING, CARE ............................................................. 91 Cleaning the motorcycle ................................................. 91 Storage......................................................................... 91

Preparing for use after storage ........................................ 92

ENGINE CONTROL BLINK CODE........................................ 93

TECHNICAL DATA - ENGINE.............................................. 95 Capacity - engine oil ...................................................... 95

Capacity - coolant.......................................................... 96

TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 97

TECHNICAL DATA - CHASSIS ............................................ 99 Tires ............................................................................ 99

Capacity - fuel............................................................. 100

TECHNICAL DATA - FORK................................................ 101

TECHNICAL DATA - SHOCK ABSORBER ........................... 102

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 103

WIRING DIAGRAM .......................................................... 106 Page 1 of 6................................................................. 106

Page 2 of 6................................................................. 108

Page 3 of 6................................................................. 110

Page 4 of 6................................................................. 112

Page 5 of 6................................................................. 114

Page 6 of 6................................................................. 116

SUBSTANCES................................................................. 118

AUXILIARY SUBSTANCES................................................ 120

STANDARDS................................................................... 121

INDEX ............................................................................ 122

3

MEANS OF REPRESENTATION Symbols used

The•symbols•used•are•explained•below.

Indicates•an•expected•reaction•(e.g.•to•a•work•step•or•a•function).

Indicates•an•unexpected•reaction•(e.g.•to•a•work•step•or•a•function).

4

All•work•marked•with•this•symbol•requires•specialist•knowledge•and•technical•understanding.

In the interests of your own safety, have these jobs done in an authorized KTM-RC8 workshop!

There,•your•motorcycle•will•be•serviced•optimally•by•specially•trained•experts•using•the•specialist•tools•required.

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

Formats used

The•typographical•and•other•formats•used•are•explained•below.

Specific name

Identifies•a•proprietary•name.

Name ®

Identifies a protected name.

Brand™

Identifies a trademark.

IMPORTANT INFORMATION Use definition

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use.

Info

The motorcycle may only be used in closed off areas remote from public road traffic.

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. Poor suspension settings can cause damage and breakage to chassis components.

Use of the motorcycles under extreme operating conditions can lead to excessive component wear. For this reason, it may be neces sary to service or replace worn parts before the limit specified in the service schedule is reached.

Pay careful attention to the prescribed running-in period and service intervals. Close adherence to these periods will significantly lengthen the service life of your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the

KTM dealer.net

; otherwise, all warranty claims will be void. No warranty claim can be met for damage result ing from manipulation and/or other changes to the vehicle.

Materials

The fuels and lubricants named in the owner's manual must be used according to specifications.

Spare parts, accessories

In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM-RC8 workshop. KTM accepts no liability for other products and any resulting damage.

Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be glad to advise you.

You will find the current

KTM PowerParts

for your vehicle on the KTM website.

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

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring compressor (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If a thread lock (e.g.

Loctite ®

) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.

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

Following repairs or servicing, the vehicle must be checked for operating safety.

Transport Note Danger of damage

  The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note Fire hazard

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

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

– – Switch off the ignition by pressing the emergency OFF switch into the position .

Secure the motorcycle against falling over or running away using straps or other suitable devices.

5

IMPORTANT INFORMATION Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and conflicts. To ensure the future of motorcycle sport, make sure you use the motorcycle legally, demonstrate a consciousness for the environment, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss ing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks Danger

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

Warning

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

Caution

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

Note

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

Warning

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

– –

Owner's manual

Be sure to read this owner's manual carefully and completely before taking your first ride. It contains useful information and tips to help you operate and handle your motorcycle. Only then will you learn how to best customize the motorcycle for your own use and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

6

VIEW OF VEHICLE

3.1

View of vehicle, front left side

1 2 3 4 5

Clutch lever ( p. 10)

Handwheel for the spring preload on the shock absorber Engine oil fuel filler

Quick shifter ( p. 83)

Shift lever ( p. 35)

601394-10

7

VIEW OF VEHICLE

3.2

View of vehicle, rear right side

1 2 2 3 4 5

Vehicle identification number/type label (

Emergency OFF switch ( p. 10) Electric starter button ( Hand brake lever ( p. 10) p. 10)

Foot brake lever (

Engine number (

p. 36)

p. 9) p. 9)

601395-10

8

SERIAL NUMBERS

4.1

Vehicle identification number/type label

The vehicle identification number on the right.

The type label 2 1 is stamped on the frame behind the steering head is on the frame above the chassis number.

9

4.2

Engine number

601396-10 The engine number 1 is stamped on the right side of the engine.

4.3

Fork part number

601397-10 The fork part number 1 is stamped on the inner side of the fork stub.

4.4

Shock absorber part number

100656-10 The shock absorber part number case under the spring.

1 is shown on a sticker applied to the shock absorber 4.5

Steering damper part number

601476-10 The steering damper part number 1 is stamped on the top of the steering damper.

601398-10

CONTROLS

5.1

Clutch lever

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

The clutch is hydraulic and self-adjusting.

5.2

Hand brake lever

601399-10 The hand brake lever 1 is fitted on the right side of the handlebar.

The hand brake lever operates the front brake.

10

5.3

Throttle grip

601400-10 The throttle grip 1 is fitted on the right side of the handlebar.

5.5

5.4

Emergency OFF switch Electric starter button

601454-10 601410-10 The emergency OFF switch

Possible states

1 is installed on the right side of the handlebar.

Emergency OFF switch (ignition) on – This setting is required for opera tion; all power consumers are supplied with current.

Emergency OFF switch (ignition) off running engine cannot be started.

– In this position, the power sup ply to all power consumers is cut, a running engine stops, and a non The electric starter button 1 is fitted on the right side of the handlebar.

Possible states

• Electric starter button • Electric starter button in neutral position pressed – In this position, the electric starter is operated.

601410-11

CONTROLS

5.6

Quick shifter switch

The quick shifter switch 1 is located on the left next to the combination instrument.

Possible states

• Quick shifter on • Quick shifter off – – The quick shifter switch is flipped up.

The quick shifter switch is flipped down.

11

601460-10 5.7

Combination instrument - overview

1 2 3 4

Display ( p. 12)

Function buttons

Indicator lamps ( Info display ( p. 13) p. 13)

400580-10 5.8

Combination instrument - function buttons on handlebar

The The

MODE LAP

button button 2 1 is fitted on the handlebar, front left.

is fitted on the handlebar, rear left.

MODE button

Changes to the next item on the info display in

ROAD LAP button

Changes to the next item on the info display in

RACE

mode.

ROAD

mode and in

RACE

mode.

mode. Clocks the lap times in 601412-10

CONTROLS

5.9

Combination instrument - activation and test Activation

The combination instrument is activated when the emergency OFF switch is switched on.

Test

The segments of the tachometer light up and switch off in sequence.

The speed display counts from 0 to 300 and back.

The remaining display segments outside the info display light up briefly.

The

KTM

logo appears in the info display.

In

ROAD

mode, the info display switches to

ODO

,

Trip 1

,

Time 1

,

Avs 1

mode.

In

RACE

mode, the info display switches to

LAPSTOGO

,

LastLap

,

±Last

,

±Best

mode.

12

5.10

Display

400429-10 The tachometer The red marking 1 2 displays the engine speed in revolutions per minute (RPM).

marks the over-rev (excessive speed) range of the engine.

The speed 3 is displayed in kilometers per hour The time appears in segment 4 .

km/h

or in miles per hour

Mph

.

Info

After reconnecting the battery or changing the fuse, the time must be reset.

The coolant temperature is shown in degrees Celsius or Fahrenheit in segment The info display 6 shows additional information.

5 .

400580-12

CONTROLS

5.11

Info display 13

The info display 1 has the If the general warning lamp cally on the info display.

ROAD

mode and

RACE

mode menu interfaces.

lights up, the corresponding message is shown periodi Information repeat 45 s The information shown on the info display can be controlled with the function buttons.

400580-13 5.12

Indicator lamps

400580-14

Possible states

The oil pressure warning lamp lights up red low.

– The oil pressure is too The shift warning light lights up/flashes red reached.

– The set shift speed is The idle speed indicator lamp lights up green shifted to idle.

– The transmission is

EFI

warning lamp (

MIL

) lights up/flashes red – The OBD (on-board diag nosis) has detected an emission- or safety-critical error.

The general warning lights up yellow play.

– An operating safety (warning) message was detected. This is also shown periodically in the info dis Indicator lamp – No function Indicator lamp – No function Indicator lamp – No function 5.13

Notes/warnings on the combination instrument LOW BATTERY

value.

appears on the info display if the battery voltage falls below the specified Battery voltage 10.80 V 400471-01

CONTROLS SERVICE IN xxx KM(MPH)

appears on the info display if the distance to the next service falls below the specified value.

Distance 500 km (310.7 mi)

14

400472-01

HIGH TEMP

fied value.

appears on the info display if the coolant temperature rises above the speci Coolant temperature 120 °C (248 °F) 400474-01

FRONT SENSOR

sensor is faulty.

appears on the info display if the front cylinder coolant temperature 400469-01

SENSOR ERROR

appears on the info display if the discrepancy between the front and rear cylinder coolant temperature sensor values is more than the specified value.

Coolant temperature 10 °C (50 °F) 400468-01

CONTROLS

5.14

Combination instrument - ROAD mode overview 15

401208-10

Functions in ROAD mode

Odometer menu,

ODO

/

Trip 1

Odometer menu,

ODO

/

Trip 2 FUELDISTANCE

menu

DISTANCE TO Next Service

menu 5.15

Odometer menu, ODO/Trip 1

400578-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is being ridden.

• –

ROAD

mode Press the

MODE

the info display.

button briefly and repeatedly until

ODO

appears at the top left of

ODO

shows the total distance covered.

Trip 1

shows the distance covered since the last reset. For example, between two refu eling stops.

Trip 1

is always running and counts up to

9999.9

.

Time 1

shows the journey time on the basis of

Trip 1

and resumes running as soon as a speed signal is received.

The calculation of this value starts with the first speed signal and ends 3 seconds after the last speed signal.

Avs 1Avs 1

shows the average speed and is coupled with

Trip 1

and

Time 1

.

Press the button . No function Press the button . No function Press the button and the button for 3 - 5 seconds.

The display changes to the

SET

UP

menu

CONTROLS 16

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

The display of

Trip 1

,

Time 1

and

Avs 1

is reset Next display mode 5.16

Odometer menu, ODO/Trip 2

400579-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is being ridden.

• –

ROAD

mode Press the

MODE

the info display.

button briefly and repeatedly until

ODO

appears at the top left of

ODO

shows the total distance covered.

Trip 2

shows the distance covered since the last reset. For example, between two refu eling stops.

Trip 2

is always running and counts up to

9999.9

.

Time 2

shows the journey time on the basis of

Trip 2

and resumes running as soon as a speed signal is received.

The calculation of this value starts with the first speed signal and ends 3 seconds after the last speed signal.

Avs 2

shows the average speed and is coupled with

Trip 2

and

Time 2

.

Press the button . No function Press the button . No function Press the button and the button for 3 - 5 seconds.

The display changes to the

SET

UP

menu Press the

MODE

button for 3 5 seconds.

The display of

Trip 2

,

Time 2

and

Avs 2

is reset Press the

MODE

button briefly.

Next display mode 5.17

FUELDISTANCE menu

401202-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is being ridden.

• –

ROAD

mode Press the

MODE

button briefly and repeatedly until of the info display.

TripFuel

- No function

OuterTemp

- No function

FUELDISTANCE

appears at the top

Tip

The

OuterTemp OuterTemp

display can be switched off in the

OPTIONS

then no longer appears on the info display.

menu.

Press the button . No function Press the button . No function

CONTROLS

Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

The display changes to the

SET

UP

menu No function Next display mode 5.18

Next service menu, DISTANCE TO Next Service

• –

Condition

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode Press the

MODE

button briefly and repeatedly until appears in the info display.

DISTANCE TO Next Service DISTANCE TO Next Service

shows the distance before the next service is necessary.

401203-01 Press the button . No function Press the button . No function Press the button and the button for 3 - 5 seconds.

The display changes to the

SET

UP

menu No function Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Next display mode

17

CONTROLS

5.19

Combination instrument - RACE mode overview 18

400943-10

Functions in RACE mode LAPSTOGO

menu Maximum lap speed menu,

TOPSPEED

Lap time,

LAP/BESTLAP/LastLap

menu Top speed,

LAP/BESTLAP/TopSpeed

Total distance in Race mode menu, menu

RACEODO

5.20

Remaining laps menu, LAPSTOGO

400444-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

RACE

mode

Alternative 2

• The ignition is on.

• – • The motorcycle is being ridden.

RACE

mode Press the

MODE

button briefly and repeatedly until of the info display.

LAPSTOGO

appears at the top left

LAPSTOGO

shows the number of remaining laps.

If an If a

P R

appears after appears after

LAPSTOGO

, the stopwatch is running in the background.

LAPSTOGO

, the stopwatch in the background is active but waiting for a speed signal. The time is not running.

This function is controlled with the

LAP

button.

LastLap

shows the lap time of the last lap.

±Last ±Best

play.

shows the difference between the last lap and the lap before last.

shows the difference between the last lap and the best lap.

If the last lap was the fastest, you see behind

±Best

: the

Best!

symbol in the info dis Press the button . No function Press the button . No function

CONTROLS 19

Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

The display changes to the

SET

UP

menu All values in

RACE

mode are reset (except

RACEODO

) Next display mode 5.21

Maximum lap speed menu, TOPSPEED

400445-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

RACE

mode

Alternative 2

• The ignition is on.

• The motorcycle is being ridden.

• –

RACE

mode Press the

MODE

button briefly and repeatedly until of the info display.

TOPSPEED

appears at the top left

TOPSPEED

shows the highest lap speed.

If an If a

P R

appears after appears after

TOPSPEED

, the stopwatch is running in the background.

TOPSPEED

, the stopwatch in the background is active but waiting for a speed signal. The time is not running.

This function is controlled with the

LAP

button.

LastLap ±Last ±Best

mum speed.

If the last lap was the lap with the highest maximum speed, the info display shows

±Best

: shows the maximum speed of the last lap.

shows the maximum speed difference between the last lap and the lap before.

shows the maximum speed difference between the last lap and the highest maxi-

Best!

Press the button . No function Press the button . No function Press the button and the button for 3 - 5 seconds.

The display changes to the

SET

UP

menu Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

The display of

LastLap

,

±Last

and

±Best

are set to

0

Next display mode 5.22

LAP/BESTLAP/LastLap menu

400446-01

Condition

• The ignition is on.

• The motorcycle is stationary.

• –

RACE

mode Press tje

MODE

button briefly and repeatedly until the info display.

LAP/BESTLAP/LastLap LAP

shows the selected lap.

BESTLAP

shows the number of the lap with the best lap time.

LastLap

shows the time of the lap behind

LAP

.

±Lap ±Lap

shows the difference to the lap before.

shows the difference to the lap after.

appears in Press the button . The next lap is displayed Press the button . The previous lap is displayed

CONTROLS

Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

The display changes to the

SET

UP

menu All values in

RACE

mode are reset (except

RACEODO

) Next display mode 5.23

Maximum speed menu, LAP/BESTLAP/TopSpeed

400447-01

Condition

• The ignition is on.

• The motorcycle is stationary.

• –

RACE

mode Press the

MODE

button briefly and repeatedly until in the info display.

LAP/BESTLAP/TopSpeed LAP

shows the selected lap.

BESTLAP

shows the lap in which the highest maximum speed was reached.

TopSpeed LAP

.

±Lap

shows maximum speed of the lap behind shows the difference to the lap before.

±Lap

shows the difference to the lap after.

appears Press the button . The next lap is displayed Press the button . The previous lap is displayed Press the button and the button for 3 - 5 seconds.

The display changes to the

SET

UP

menu All values in

RACE

mode are reset (except

RACEODO

) Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Next display mode 5.24

Total distance in Race mode menu, RACEODO

400448-01 • –

Condition

• The ignition is on.

• The motorcycle is stationary.

RACE

mode Press the

MODE

the info display.

button briefly and repeatedly until

RACEODO

appears at the top of

RACEODO RaceTrip MaxRPM

shows the total distance covered in shows the distance covered since the last reset. For example, between two refueling stops.

RaceTrip RACE

mode.

is always running and counts up to shows the highest engine speed reached during the

999.9

.

RaceTrip

.

TopSpeed

shows the highest speed reached during the

RaceTrip

.

Press the button . No function Press the button . No function Press the button and the button for 3 - 5 seconds.

The display changes to the

SET

UP

menu All values in

RACE

mode are reset (except

RACEODO

) Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Next display mode

20

CONTROLS

5.25

Combination instrument - SET

UP mode 21

401209-01

Settings in SET

UP mode

Mode menu,

CHANGE MODE

Time menu,

SET CLOCK SETTINGS

menu

UNITS

menu

OPTIONS

menu

EXIT SETUP

menu 5.26

SET

UP menu

400449-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• –

RACE

mode Press the button and the button for 3 - 5 seconds.

In the

CHANGE MODE

menu, you can select between

ROAD

and

RACE

mode.

You can set the clock on the On the

LAP

In the

UNITS SET CLOCK

menu.

SETTINGS

menu, you can set the shift warning light, the lap blank time of the button, the number of laps, and the reset time of the fuel reserve display.

menu, you can set the units for measuring speed, distance, and tempera ture.

In the Select

OPTIONS

menu, you can switch the tire pressure check and external temperature display on/off (available as accessories).

EXIT SETUP

to close the

SET

UP

menu.

The symbol indicates which menu can be activated with the

MODE

button.

Press the button . The arrow moves up Press the button . The arrow moves down

CONTROLS

Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

No function The menu in front of the arrow is selected The menu in front of the arrow is selected 5.27

Mode menu, CHANGE MODE

400475-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• – • The motorcycle is stationary.

RACE

mode Press the button and the button – Press the

MODE

button briefly.

for 3 - 5 seconds.

In the

CHANGE MODE

menu, you can select between

ROAD

and

RACE

mode.

Press the button . Changes the menu Press the button . Changes the menu Press the button and the button for 3 - 5 seconds.

No function Open and exit

CHANGE MODE

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Open and exit

CHANGE MODE

5.28

Time menu, SET CLOCK

400455-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• – – –

RACE

mode Press the button Press the button and the button for 3 - 5 seconds.

once until the symbol Press the

MODE

button briefly.

You can set the clock in the

SET CLOCK

menu.

shows

SET CLOCK

in the info display.

Press the button . Increases the value Press the button . Decreases the value Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

No function Open and exit

SET CLOCK

or change to the next value

22

CONTROLS

Press the

MODE

button briefly.

Open and exit

SET CLOCK

or change to the next value 5.29

SETTINGS menu

400456-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• – –

RACE

mode Press the button Press the button info display.

and the button for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

in the – Press the

MODE

button briefly.

In the In the In the

SHIFT RPMS

menu, you can activate the shift warning light.

LAP BLANK TIME SET NUM LAPS

menu, you can set the lap blank time of the

LAP

menu, you can set the number of laps to cover in button.

RACE

mode.

In the In the

TRIP F RESET

menu, you can set the reaction time of the fuel reserve display to changes in the fuel level.

BACK…

menu, you can switch back to the

SET

UP

menu.

The symbol indicates which menu can be activated with the

MODE

button.

Press the button . The arrow moves up Press the button . The arrow moves down Press the button and the button for 3 - 5 seconds.

No function Press the

MODE

button for 3 5 seconds.

The menu in front of the arrow is selected Press the

MODE

button briefly.

The menu in front of the arrow is selected 5.30

Shift warning lamp menu, SHIFT RPMS

400460-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

– – • – – • The motorcycle is stationary.

RACE

mode Press the button Press the button info display.

and the button for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

in the Press the Press the

MODE MODE

button briefly.

button briefly.

In the

SHIFT RPMS

menu, you can activate the shift warning light.

Press the button . Increases the value Press the button . Decreases the value Press the button and the button for 3 - 5 seconds.

No function

23

CONTROLS

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Open and exit

SHIFT RPMS

or change to the next value Open and exit

SHIFT RPMS

or change to the next value 5.31

LAP button blank time, LAP BLANK TIME menu

400461-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

– – – • – – • The motorcycle is stationary.

RACE

mode Press the button Press the button info display.

and the button for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

in the Press the

MODE

Press the button Press the

MODE

button briefly.

once until the symbol button briefly.

shows

LAP BLANK T

in the info display.

In the

LAP BLANK TIME

menu, you set the lap blank time of the

LAP

button.

Press the button . Increases the value Press the button . Decreases the value Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

No function Open and exit

LAP BLANK TIME

Press the

MODE

briefly.

button Open and exit

LAP BLANK TIME

5.32

Number of laps menu, SET NUM LAPS

400462-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

– – – – • The motorcycle is stationary.

RACE

mode Press the button Press the button info display.

and the button for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

Press the play.

MODE

Press the button button briefly.

twice until the symbol shows

SET NUM LAPS

in the in the info dis – Press the

MODE

button briefly.

In the

SET NUM LAPS

menu, you can set the number of laps to cover in

RACE

mode.

Press the button . Increases the value Press the button . Decreases the value

24

CONTROLS

Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

No function Open and exit

SET NUM LAPS

Open and exit

SET NUM LAPS

5.33

Fuel reserve display menu, TRIP F RESET

400463-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• – –

RACE

mode Press the button Press the button info display.

and the button for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

in the – – Press the

MODE

Press the button display.

button briefly.

three times until the symbol shows

TRIP F RESET

in the info – Press the

MODE

button briefly.

In the

TRIP F RESET

menu, you can set the reaction time of the fuel reserve display to changes in the fuel level.

Info

In this model, the fuel reserve cannot be measured.

Press the button . Increases the value Press the button . Decreases the value Press the button and the button for 3 - 5 seconds.

No function Press the

MODE

button for 3 5 seconds.

Open and exit

TRIP F RESET

Press the

MODE

button briefly.

Open and exit

TRIP F RESET

5.34

UNITS menu

400458-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode • – –

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

RACE

mode Press the button Press the button and the button for 3 - 5 seconds.

three times until the symbol shows

UNITS

in the info display.

25

CONTROLS

– Press the

MODE

button briefly.

In the In the In the

SET KM/MILES SET °C/°F BACK…

The symbol menu, you can set the units for measuring speed and distance.

menu, you can set the unit for the temperature display.

menu, you can switch back to the

SET

UP

menu.

indicates which menu can be activated with the

MODE

button.

Press the button . The arrow moves up Press the button . The arrow moves down Press the button and the button for 3 - 5 seconds.

No function The menu in front of the arrow is selected Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

The menu in front of the arrow is selected 5.35

Kilometers/miles menu, SET KM/MILES

400464-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• – – – –

RACE

mode Press the button Press the button Press the Press the

MODE MODE

and the button three times until the symbol button briefly.

button briefly.

for 3 - 5 seconds.

shows

UNITS

in the info display.

In the

SET KM/MILES

menu, you can set the units for measuring speed and distance.

Press the button . Changes the unit Press the button . Changes the unit Press the button and the button for 3 - 5 seconds.

No function Open and exit

SET KM/MILES

Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Open and exit

SET KM/MILES

5.36

Temperature display menu, SET °C/°F

400465-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• – – • The motorcycle is stationary.

RACE

mode Press the button Press the button and the button for 3 - 5 seconds.

three times until the symbol shows

UNITS

in the info display.

26

CONTROLS

– – – Press the

MODE

Press the button button briefly.

once until the symbol Press the

MODE

button briefly.

shows

SET °C/°F

in the info display.

In the

SET °C/°F

menu, you can set the unit for the temperature display.

Press the button . Changes the unit Press the button . Changes the unit Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

No function Open and exit

SET °C/°F

Press the

MODE

briefly.

button Open and exit

SET °C/°F

5.37

Additional functions menu, OPTIONS

400459-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• – –

RACE

mode Press the button Press the button play.

and the button for 3 - 5 seconds.

four times until the symbol shows

OPTIONS

in the info dis – Press the

MODE

button briefly.

In the accessory).

In the

OPTION OUTTEMP

In the

OPTION TPMS BACK…

menu, you can switch the tire pressure check on/off (available as menu, you can switch the external temperature display on/off.

menu, you can switch back to the

SET

UP

menu.

The symbol indicates which menu can be activated with the

MODE

button.

Press the button . The arrow moves up Press the button . The arrow moves down Press the button and the button for 3 - 5 seconds.

Press the

MODE

button for 3 5 seconds.

No function The menu in front of the arrow is selected Press the

MODE

button briefly.

The menu in front of the arrow is selected 5.38

Tire pressure monitor menu, TPMS Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

400478-01

27

CONTROLS 28

• – –

RACE

mode Press the button Press the button play.

and the button for 3 - 5 seconds.

four times until the symbol shows

OPTIONS

in the info dis – – Press the Press the

MODE MODE

button briefly.

button briefly.

In the

OPTION TPMS

accessory).

menu, you can switch the tire pressure check on/off (available as Press the button . Switches the tire pressure display on/off Press the button . Switches the tire pressure display on/off Press the button and the button for 3 - 5 seconds.

No function Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Open and exit

OPTION TPMS

Open and exit

OPTION TPMS

5.39

External temperature display menu, OPTION OUTTEMP

401204-01

Condition Alternative 1

• The ignition is on.

• The motorcycle is stationary.

ROAD

mode

Alternative 2

• The ignition is on.

• The motorcycle is stationary.

• – –

RACE

mode Press the button Press the button play.

and the button for 3 - 5 seconds.

four times until the symbol shows

OPTIONS

in the info dis – – Press the

MODE

button briefly.

Press the button play.

once until the symbol shows

OPTION OUTTEMP

in the info dis – Press the

MODE

button briefly.

In the

OPTION OUTTEMP

menu, you can switch the external temperature display on/off.

Info

In this model, the external temperature cannot be measured.

Press the button . Switches the external temperature display on/off Press the button . Switches the external temperature display on/off Press the button and the button for 3 - 5 seconds.

No function Press the

MODE

button for 3 5 seconds.

Press the

MODE

button briefly.

Open and exit

OPTION OUTTEMP

Open and exit

OPTION OUTTEMP

CONTROLS Table of functions Display

Odometer menu,

ODO

Odometer menu,

ODO FUELDISTANCE

Next service menu,

Next Service

Remaining laps menu,

LAPSTOGO

Maximum lap speed menu,

LAP

menu Maximum speed menu,

LAP

Total distance in

Race RACEODO SET

Mode menu,

CHANGE MODE

Time menu,

SETTINGS

Shift warning lamp menu,

LAP

/ / ‑ / /

Trip 1 Trip 2 BESTLAP BESTLAP

mode menu,

UP DISTANCE TO TOPSPEED

menu / / menu

LastLap TopSpeed SET CLOCK

menu

SHIFT RPMS

button blank time,

LAP BLANK TIME UNITS

menu menu Number of laps menu,

SET NUM LAPS

Fuel reserve display menu,

TRIP F RESET

Kilometers/miles menu,

SET KM/MILES

Temperature display menu,

SET °C/°F Press the button .

No function No function No function No function No function No function The next lap is displayed The next lap is displayed No function The arrow moves up Changes the menu The arrow moves up The arrow moves up Changes the unit Changes the unit

Press the button .

No function No function No function No function No function No function The previous lap is displayed The previous lap is displayed No function The arrow moves down Changes the menu Increases the value Decreases the value The arrow moves down Increases the value Decreases the value Increases the value Decreases the value Increases the value Decreases the value Increases the value Decreases the value The arrow moves down Changes the unit Changes the unit

Press the button and the button 3 - 5 seconds.

The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu

for

The display changes to the

SET

UP

menu The display changes to the

SET

UP

menu No function No function No function No function No function No function No function No function No function No function No function

Press the MODE but ton for 3 - 5 sec onds.

The display of

Trip 1

,

Time 1

and

Avs 1

is reset The display of

Trip 2

,

Time 2

and

Avs 2

is reset No function No function All values in mode are reset (except

RACE RACEODO

) The display of

LastLap

,

±Last

and

±Best

are set to

0

All values in

RACE

mode are reset (except

RACEODO

) All values in mode are reset (except

RACE RACEODO

) All values in mode are reset (except

RACE RACEODO

) The menu in front of the arrow is selected Open and exit

CHANGE MODE

Open and exit

SET CLOCK

value or change to the next The menu in front of the arrow is selected Open and exit

SHIFT RPMS

value or change to the next Open and exit

LAP BLANK TIME

Open and exit

SET NUM LAPS

Open and exit

TRIP F RESET

The menu in front of the arrow is selected Open and exit

SET KM/MILES

Open and exit

SET °C/°F Press the MODE but ton briefly.

Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode The menu in front of the arrow is selected Open and exit

CHANGE MODE

Open and exit

SET CLOCK

value or change to the next The menu in front of the arrow is selected Open and exit

SHIFT RPMS

value or change to the next Open and exit

LAP BLANK TIME

Open and exit

SET NUM LAPS

Open and exit

TRIP F RESET

The menu in front of the arrow is selected Open and exit

SET KM/MILES

Open and exit

SET °C/°F 29

CONTROLS Table of functions Display

Additional functions menu,

OPTIONS Press the button .

The arrow moves up

Press the button .

The arrow moves down

Press the button and the button 3 - 5 seconds.

No function

for

Tire pressure monitor menu,

TPMS

External temperature display menu,

OPTION OUTTEMP

Switches the tire pressure display on/off Switches the exter nal temperature display on/off

Table of conditions and menu activation Display

• The ignition • The motorcy cle is station ary.

• is on.

ROAD

mode Odometer menu,

ODO

/

Trip 1

Odometer menu,

ODO

/

Trip 2 FUELDISTANCE

menu Next service menu,

DISTANCE TO Next Service

• • • • Remaining laps menu,

LAPSTOGO

Maximum lap speed menu,

TOPSPEED LAP

/

BESTLAP

/

LastLap

menu Maximum speed menu,

BESTLAP

/

TopSpeed LAP

/ Total distance in menu,

RACEODO SET

UP

menu

Race

mode Mode menu,

CHANGE MODE

Time menu,

SET CLOCK

• • • •

SETTINGS

menu Shift warning lamp menu,

SHIFT RPMS LAP

button blank time,

LAP BLANK TIME

menu Number of laps menu,

SET NUM LAPS

Fuel reserve display menu,

TRIP F RESET UNITS

menu Kilometers/miles menu,

SET KM/MILES

Temperature display menu,

SET °C/°F

Additional functions menu,

OPTIONS

Tire pressure monitor menu,

TPMS

External temperature display menu,

OPTION OUTTEMP

• • • • • • • • • • Switches the tire pressure display on/off Switches the exter nal temperature display on/off • The ignition • is on.

• The motorcy cle is being ridden.

ROAD

• • • mode No function No function • The ignition • is on.

• The motorcy cle is station ary.

RACE

• • • • • • • • • • • • • • • • • • • mode

Press the MODE but ton for 3 - 5 sec onds.

The menu in front of the arrow is selected Open and exit

OPTION TPMS Press the MODE but ton briefly.

The menu in front of the arrow is selected Open and exit

OPTION TPMS

Open and exit

OPTION OUTTEMP

• The ignition is on.

• The motorcy cle is being ridden.

RACE

• • mode Open and exit

OPTION OUTTEMP Menu can be acti vated

• • •

30

CONTROLS

5.40

Displaying lap times

400446-01

Condition

The ignition is on.

The motorcycle is stationary.

RACE

mode – Press tje

MODE

button briefly and repeatedly until the info display.

LAP01

appears on the left of the info display.

– Press the button .

LAP/BESTLAP/LastLap

appears in – – The next lap is displayed.

Press the button .

The previous lap is displayed.

Press the

MODE

button briefly.

Next display mode 5.41

Displaying maximum speed

400447-01 5.43

Setting the clock with SET CLOCK Condition

The ignition is on.

The motorcycle is stationary.

RACE

mode – Press the

MODE

button briefly and repeatedly until in the info display.

LAP/BESTLAP/TopSpeed

appears – – –

LAP01

appears on the left of the info display.

Press the button .

The next lap is displayed.

Press the button .

The previous lap is displayed.

Press the

MODE

button briefly.

Next display mode 5.42

Setting ROAD or RACE mode

400475-01 – –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button – Press the

MODE

button briefly.

– – for 3 - 5 seconds.

The mode set is shown in the info display.

Select

ROAD

mode or Press the

MODE

button briefly.

The settings are stored and the display changes to the

SET

UP

menu.

Press the button the info display.

RACE

mode with the button or the button .

briefly and repeatedly until the symbol Press the

MODE

button briefly.

shows

EXIT SETUP

in – – – –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button Press the button Press the

MODE

for 3 - 5 seconds.

once until the symbol button briefly.

shows

SET CLOCK

in the info display.

The hour is shown.

Set the hour with the button Press the

MODE

button briefly.

The minutes are shown.

or the button .

400455-01

31

CONTROLS 32

– – – – Set the minutes with the button Press the

MODE

button briefly.

The settings are stored and the display changes to the

SET

UP

menu.

Press the button the info display.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

or the button .

shows

EXIT SETUP

in 5.44

Adjusting the shift speed RPM1/2

400460-01 – – – – – – – –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button – Press the button info display.

for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

Press the Press the

MODE MODE

button briefly.

button briefly.

in the

RPM1

and

RPM2

appear on the info display.

The engine speed after

RPM1

flashes.

Info

The engine speed can be set at intervals of 50.

RPM1

is the engine speed above which the shift warning light starts to flash.

Set the engine speed with the button Press the

MODE

button briefly.

or the button .

The engine speed after

RPM2

flashes.

Info RPM2

is the engine speed above which the shift warning light lights up con stantly. If

RPM1

=

RPM2

, the shift warning light lights up constantly when you reach the engine speed set.

Set the engine speed with the button Press the

MODE

button briefly.

or the button .

The settings are stored and the display switches to the

SETTINGS

menu.

Info

At delivery,

RPM1

is set to 10000 and

RPM2

to 10500.

– shows

BACK...

in the – Press the button info display.

Press the button the info display.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

shows

EXIT SETUP

in 5.45

Setting the blank time of the LAP button LAP BLANK TIME

– – –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button – Press the button info display.

for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

in the Press the Press the button Press the

MODE MODE

button briefly.

once until the symbol button briefly.

shows

LAP BLANK T

in the info display.

LAP BLANK T.

appears in the info display.

400461-01

Info

At delivery,

LAP BLANK T.

is set to

1

second.

CONTROLS

Tip

With the

LAP BLANK TIME

function, you can prevent the lap from being timed too short. This may happen if you accidentally press the

LAP

button twice in a row.

Set the blank time of the

LAP

button with the button or the

Info LAP BLANK T.

can be set between

1

and

200

.

button.

– – – – – Press the

MODE

button briefly.

The settings are stored and the display changes to the

SETTINGS

menu.

Press the button info display.

briefly and repeatedly until the symbol shows

BACK...

in the Press the

MODE

button briefly.

Press the button the info display.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

shows

EXIT SETUP

in 5.46

Setting the number of laps SET NUM LAPS

– –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button – Press the button info display.

for 3 - 5 seconds.

twice until the symbol appears in front of

SETTINGS

Press the play.

MODE

Press the button button briefly.

twice until the symbol shows

SET NUM LAPS

in the in the info dis – Press the

MODE

button briefly.

TOTAL LAPS

appears on the info display with the number of laps.

400462-01

Info

When delivered, the number of

TOTAL LAPS

is set to 99 laps.

– Set the number of laps with the button or the button .

Info

You can set

TOTAL LAPS

to between 1 and 99 laps.

– – – – – Press the

MODE

button briefly.

The settings are stored and the display switches to the

SETTINGS

menu.

Press the button info display.

Press the

MODE

button briefly.

Press the button the info display.

briefly and repeatedly until the symbol briefly and repeatedly until the symbol shows

BACK...

in the shows

EXIT SETUP

in Press the

MODE

button briefly.

5.47

Setting the kilometers/miles SET KM/MILES Info

Making a country-specific setting.

Condition

The ignition is on.

The motorcycle is stationary.

33

CONTROLS 34

400464-01 – – – – – – – – – – Press the button Press the button and the button Press the

MODE

button briefly.

Press the

MODE

button briefly.

for 3 - 5 seconds.

three times until the symbol shows The selected unit appears on the left in the display.

Select the unit with the button or the button .

UNITS

in the info display.

Press the

MODE

button briefly.

The settings are stored and the display changes to the Press the button info display.

briefly and repeatedly until the symbol

UNITS

menu.

shows

BACK...

in the Press the

MODE

button briefly.

Press the button the info display.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

shows

EXIT SETUP

in 5.48

Setting the temperature unit SET °C/°F

400465-01 – – – –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button – Press the button for 3 - 5 seconds.

three times until the symbol shows – Press the

MODE

button briefly.

– Press the button once until the symbol shows

UNITS SET °C/°F

in the info display.

in the info display.

– Press the

MODE

button briefly.

The selected unit appears on the left in the display.

Select the unit with the button or the button .

Press the

MODE

button briefly.

– – The settings are stored and the display changes to the

UNITS

Press the button info display.

briefly and repeatedly until the symbol menu.

shows

BACK...

in the Press the

MODE

button briefly.

Press the button the info display.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

shows

EXIT SETUP

in 5.49

Hiding the external temperature display

– –

Condition

The ignition is on.

The motorcycle is stationary.

– Press the button and the button – Press the button play.

for 3 - 5 seconds.

four times until the symbol shows

OPTIONS

Press the play.

MODE

Press the button button briefly.

once until the symbol shows in the info dis-

OPTION OUTTEMP

in the info dis – Press the

MODE

button briefly.

You see

ENABLED

or

DISABLED

on the info display.

401204-01

Info

In this model, the external temperature cannot be measured.

– – – You can show or hide the external temperature display with the button the button .

Press the

MODE

button briefly.

or The settings are stored and the display changes to the

OPTIONS

menu.

Press the button info display.

briefly and repeatedly until the symbol shows

BACK...

in the

CONTROLS 35

– – – Press the

MODE

button briefly.

Press the button the info display.

briefly and repeatedly until the symbol Press the

MODE

button briefly.

shows

EXIT SETUP

in 5.50

Opening the filler cap Danger Fire hazard

  Fuel is highly flammable.

– – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Warning Environmental hazard

  Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– – Press the filler cap lever 1 and turn 90° counterclockwise.

Remove the filler cap.

5.52

5.51

Closing the filler cap Shift lever

601413-10 601413-10 – –

Warning Fire hazard

  Fuel is highly flammable, poisonous and harmful to your health.

– When closing the filler cap, ensure that it is closed correctly. Change clothing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.

Insert the filler cap.

Turn the filler cap lever 1 90° clockwise until it engages.

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

601415-10

CONTROLS

5.53

Foot brake lever 36

The gear positions can be seen in the figure.

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

Info

The arrangement of the gears is the reverse of that in RC8 R, which is approved for public road use.

601414-10 The foot brake lever 1 is in front of the right footrest.

The foot brake lever operates the rear brake.

601416-10

PREPARING FOR USE

6.1

Advice on first use Danger Danger of accidents

  Danger arising from the rider's judgement being impaired.

– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.

Warning Risk of injury

  Missing or poor protective clothing present an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be undamaged and meet legal requirements.

Warning Danger of accidents

  Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.

– Only tires/wheels approved by KTM and with the corresponding speed index should be used.

Warning Danger of accidents

  Critical riding behavior due to inappropriate riding.

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

Warning Danger of accidents

  Accident risk caused by presence of a passenger.

– Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning Risk of misappropriation

  Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

37 Info

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

– – – – – – – – – Make sure that the pre-delivery inspection work has been carried out exclusively by an authorized KTM-RC8 workshop.

You receive a delivery certificate and the service record at vehicle handover.

Before your first trip, read the entire operating instructions carefully.

Get to know the controls.

Adjust the basic position of clutch lever. ( p. 63)

Adjust the basic position of hand brake lever. ( p. 65)

Adjust the foot brake lever. (

Adjust the shift lever. ( p. 49)

p. 51)

Check and tune the setting of the quick shifter.

x ( p. 84)

Become accustomed to the handling of the vehicle on suitable terrain. Try also to ride as slowly as possible to get a better feeling for the motorcycle.

Info

Your motorcycle is not authorized for riding on public roads.

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

Run the engine in. ( p. 38)

PREPARING FOR USE

– 6.2

Running the engine in

Do not exceed the specified engine speed and load during the running-in period.

Guideline Maximum engine speed During the first: 250 km (155.3 mi) After the first: 250 km (155.3 mi) 7,500 rpm 10,500 rpm – Avoid full-throttle operation!

38

RIDING INSTRUCTIONS 39

7.1

Checks and maintenance measures 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 it is being operated.

– – – – – – – – – – – –

Check the engine oil level. ( p. 87)

Check the front brake fluid level. ( p. 66)

Check the rear brake fluid level. ( Check the front brake linings. (

Check the rear brake linings. (

Check the brake system.

p. 67) p. 67)

p. 68)

Check the coolant level. (

Check the chain for dirt. (

Check the chain tension. (

Check the tire condition. (

p. 80)

p. 60)

p. 61)

p. 73)

Check the tire pressure. ( p. 74)

Warm the tires to the operating temperature with a tire warmer.

Guideline Tire temperature – – – – Tire warmer set (58609085100) Check the adjustment and smooth operation of all controls.

Check that the electrical equipment is functioning properly.

Check the fuel level.

Check the fuel overflow reservoir. ( p. 60)

78… 80 °C (172… 176 °F) 7.2

Starting Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Caution Danger of accidents

  If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.

– Never operate the vehicle with a discharged battery or without a battery.

Note Engine failure

  High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

RIDING INSTRUCTIONS 40

– – – Switch on the ignition by pressing the emergency OFF switch into the position .

After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function test of the combination instrument is run at the same time.

Shift into neutral.

The green idling speed indicator lamp

N

Press the electric starter button .

1 lights up.

Info

Do not press the electric starter button until the combination instrument function test finishes.

When starting,

DO NOT

engine will not start.

before trying again.

open the throttle. If you apply the throttle during the starting procedure, the engine management shuts off the injectors and the Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds 601423-10 7.3

Refueling Danger Fire hazard

  Fuel is highly flammable.

– – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Note Material damage

  Premature clogging of the fuel filter.

– – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be pleased to help.) Only refuel with clean fuel that meets the specified standards.

Warning Environmental hazard

  Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– – – – Switch off the engine.

Open the filler cap. ( p. 35)

Fill the fuel tank with fuel up to the lower edge 1 of the fuel filler.

Total fuel tank capacity, approx.

Close the filler cap. (

16.5 l (4.36 US gal)

p. 35)

Super unleaded (ROZ 100) ( p. 119)

601422-10

SERVICE SCHEDULE

8.1

Service schedule

Check that the electrical equipment is functioning properly.

Read out the trouble code memory using the KTM diagnostics tool.

x Check the measured service values with the KTM diagnostics tool.

Change the engine oil and filter, clean the oil screen.

x

( p. 87)

x Check the oil jet for the clutch lubrication.

x

Check the front brake linings. ( p. 67)

Check the front brake discs. ( p. 65)

Check the rear brake linings. (

Check the rear brake disc. (

p. 68)

p. 65)

Check that brake lines are undamaged and free of leaks.

Check the rear brake fluid level. ( p. 67)

Check the free travel of the foot brake lever.

Check that the shock absorber and fork are leak tight. If necessary and depending on use, service the fork and shock absorber.

Check the swingarm bearing.

Check the wheel bearings for play.

Check the tire condition. (

x

p. 73)

x

Check the tire pressure. ( p. 74)

Check the chain, rear sprocket and engine sprocket. (

Check the chain tension. ( p. 61)

p. 62)

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

x Clean the dust boots of the fork legs.

Check the front brake fluid level. ( p. 66)

Bleed the fork legs. ( p. 54)

Check the steering head bearing play.

Check the cylinder and piston. (under difficult riding conditions) x Check the cylinder and piston.

x Check the connecting rod, conrod bearing, and crank pin.

x Check the crankshaft bearing.

x Check the transmission and shift mechanism.

x Check the oil pressure regulator valve.

x Check the oil pumps and lubrication system.

x Check the timing assembly.

x Check all engine bearings.

x Change the spark plugs.

x Change the valves, valve springs, and valve spring seats.

x Check the camshaft and cam lever.

x Check the cylinder head.

Check the valve clearance.

x x Check the clutch.

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

x Drain the drainage hose of the air filter box.

x Check the antifreeze and coolant level.

Check the wiring harness of the throttle valve body for damage and correct routing.

Check cables for damage and kink-free routing.

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

x

Check the play in the throttle cable. ( p. 83)

Check the air filter and air filter box.

x

K025N

• • • • • • • • • • • • • • • • • • • • •

K10A

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

K50A

• • • • • • • • • • • • • • • • • • • • • • • • • • • •

K100A

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

41

SERVICE SCHEDULE

Check the fuel pressure.

x Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics tool.

x

Check the fluid level of the hydraulic clutch. ( p. 64)

Change the hydraulic clutch fluid.

x Check screws and for tightness.

x Change the front brake fluid.

x Change the rear brake fluid.

x Check radiator fan operation.

x Final check: Check the vehicle for safe operation and take a test ride.

Read out the fault memory using the KTM diagnostics tool after a test ride.

x Set the service interval display.

Make the service entry in x

KTM DEALER.NET

and in the service record.

x

K025N: K10A:

Once after 250 km (155 mi) Every 1,000 km (621.4 mi) or every year

K50A: K100A:

Every 5,000 km (3,107 mi) Every 10,000 km (6,214 mi)

K025N K10A

• • • • • • • • • • • • • • • • •

K50A

• • • • • • • • • • • •

K100A

• • • • • • • • • • • •

42

TUNING THE CHASSIS 43

9.1

Adjusting the compression damping of the fork Info

The hydraulic compression damping determines the fork suspension behavior.

An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when the load shifts very fast. It gives the rider good feedback about the road conditions.

100682-10 – – Turn adjusting screws 1 clockwise to the stop.

Info

The adjusting screws are located at the bottom end of the fork legs.

Adjust both fork legs to the same setting.

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

Guideline Compression damping Standard 3 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

9.2

Adjusting the rebound damping of the fork Info

The hydraulic rebound damping determines the fork suspension behavior.

An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the zero position.

601398-11 – – Turn adjusting screws 1 clockwise to the stop.

Info

The adjustment screws are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

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

Guideline Rebound damping Standard 9 clicks

Info

Turn clockwise to increase suspension damping; turn counterclockwise to reduce damping.

9.3

Adjusting the spring preload of the fork Info

Spring preload determines the initial fork position.

The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.

601398-12 – – Turn adjusting screws 1 clockwise to the stop.

Info

The adjustment screws are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

Turn back counterclockwise by the number of turns according to the fork type.

Guideline Spring preload -

Preload Adjuster

Standard 4 turns

TUNING THE CHASSIS 44 Info

Turn clockwise to increase preload, turn counterclockwise to reduce spring preload.

Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work. However, you should also adjust the rebound damping when you alter the spring preload.

9.4

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 compresses more quickly.

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

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

9.5

Adjusting the low-speed compression damping of the shock absorber Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.)

Info

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

601417-10 – – Turn adjusting screw 1 clockwise up to the last perceptible click.

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

Guideline Compression damping, low-speed Standard 8 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

9.6

Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.)

Info

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

601417-11 – – Turn adjusting screw 1 clockwise up to the last perceptible click.

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

Guideline Compression damping, high-speed Standard 10 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

TUNING THE CHASSIS 45

9.7

Adjusting the rebound damping of the shock absorber Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.) 601418-10 – – Turn adjusting screw 1 clockwise up to the last perceptible click.

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

Guideline Rebound damping Standard 12 clicks

Info

Turn clockwise to increase suspension damping; turn counterclockwise to reduce damping.

9.8

Adjusting the spring preload of the shock absorber

x

Warning Danger of accidents

  Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

Info

The spring preload defines the initial situation of the spring process on the shock absorber.

An optimally adjusted spring preload is adapted to the rider's weight and ensures a compromise between easy handling and stability.

– – – Release lock 1 by pressing in the direction of the arrow and turn handwheel the way in the

LOW

direction.

2 all Let go of the lock 1 .

Turn handwheel 2 in the

HIGH

direction until the handwheel engages.

Info

Turn clockwise to increase preload; turn counterclockwise to reduce spring preload.

601477-10

TUNING THE CHASSIS

9.9

Steering damper 46

The steering damper suppresses shocks to the steering arising from acceleration on uneven ground at high speed or when the load is temporarily taken from the front wheel.

The steering damper is adjusted to suit the riding style and the road conditions. For high speeds, a setting with high damping can be chosen to make the best possible use of the steering damper function. In slow, tight bends, intensive damping can negatively affect handling and steering precision, so the damping should be set to low.

601398-01 9.10

Adjusting the steering damper Info

The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load.

In contrast to other damping elements, the steering damper is adjusted with the damping element open.

601419-10 – – Turn the adjusting screw tible click.

1 counterclockwise towards " – " as far as the last percep Adjust the steering damper according to your riding style and the road conditions by turning the adjust screw clockwise towards "

+

".

Guideline Steering damper adjustment range 1… 32 clicks Recommended range for use Standard 1… 20 clicks 1 click

Info

Do not change the adjustment of the steering damper during the journey!

After adjusting the steering damper, check the steering for smooth oper ation, making sure that the handlebar can be moved from extreme left to extreme right without a tendency to lock.

9.11

Vehicle level

601420-01

Warning Danger of accidents

  Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

The vehicle level can be adjusted at the front by means of the fork leg clamp and at the rear by the eccentric shaft.

The fork legs can be clamped at three positions in the triple clamp.

Upper triple clamp flush with upper edge of fork legs Upper triple clamp flush with 1st ring of fork legs Upper triple clamp flush with 2nd ring of fork legs (standard) 0 mm (0 in) 2.5 mm (0.098 in) 5 mm (0.2 in) The infinitely variable frame height setting can be adjusted by turning the eccentric shaft.

Frame height difference

HIGH

-

LOW

12 mm (0.47 in) Maximum adjustment range between

HIGH

-

LOW

180°

TUNING THE CHASSIS

9.12

Adjusting front vehicle level

x

Warning Danger of accidents

  Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

601421-10 601424-10 601421-10 – – – Loosen screws 1 on the lower triple clamp.

Loosen screw 2 on the upper triple clamp.

Loosen screw 3 of the handlebar stub.

Info

Loosen the screws far enough to prevent damage to the lacquer when the fork legs are moved.

Make the adjustments first on one fork leg and then on the other. When the screws of both fork legs are loosened, the vehicle sags toward the front.

– Align the fork leg in the desired position by means of the fork rings.

Guideline Upper triple clamp flush with upper edge of fork legs Upper triple clamp flush with 1st ring of fork legs 0 mm (0 in) 2.5 mm (0.098 in) Upper triple clamp flush with 2nd ring of fork legs (standard) 5 mm (0.2 in) – – – –

Info

The standard adjustment is the setting that provides the best vehicle han dling. When the fork is compressed, the suspension setting changes, caus ing the vehicle to become more stable but also more difficult to handle.

Tighten screw 2 .

Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) Tighten screws 1 .

Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) Tighten screw 3 .

Guideline Screw, handlebar stub M8 20 Nm (14.8 lbf ft) Repeat the adjustment on the other fork leg.

Info

The vehicle level setting on both fork legs must be identical.

9.13

Adjusting the vehicle level at the rear Warning Danger of accidents

  Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

47

TUNING THE CHASSIS

– Loosen screw 1 but do not remove it.

48

601425-10 601426-10 – Turn eccentric shaft 2 to the desired position using the tool from the tool set.

Guideline Standard Maximum adjustment range between

HIGH

-

LOW LOW

180° Open end wrench SW 38 (69012021000) –

Info

The chassis height can be adjusted in both directions.

Tighten screw 1 .

Guideline Screw, clamp, eccentric shaft of deflector M8 18 Nm (13.3 lbf ft) 9.14

Footrest position

601427-10 The adjustable footrest system enables an individual setting of the footrest position and an individual adjustment of the controls.

The footrest holder can be mounted in 9 different positions on the footrest bracket.

The lower footrest position enables a more comfortable knee angle, the upper footrest position a sporting sitting position and more forward-leaning freedom for use in racing.

601428-10 9.15

Adjusting the footrest position Info

The footrest position must be identical on the left and the right.

Main work

– Remove screws – 1 .

Position footrest holder 2 . Mount and tighten screws 1 .

Guideline Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) – Repeat the operation on the opposite side.

601428-11

Subsequent work

Adjust the foot brake lever. (

Adjust the shift lever. (

p. 51)

p. 49)

Loctite ® 243™

TUNING THE CHASSIS

9.16

Adjusting the shift lever stub

– – Remove cap 1 Remove screw .

2 with the shift lever stub.

601429-10 – Position the shift lever stub with the screw into drill hole on the desired lever length.

A , B , or C , depending

49

601430-10 – Tighten screw 2 .

Guideline Screw, shift lever stub – Mount cap 1 .

M6 9.17

Adjusting the shift lever

601429-10 – Loosen nuts 1 .

10 Nm (7.4 lbf ft)

Loctite ® 243™

601431-10 – Turn shift rod 2 while installed until the shift lever is in the desired position.

Guideline Shift rod length A ≤ 132 mm ( ≤ 5.2 in)

Info

If the adjustment range of the shift rod is insufficient, the positioning of the shift rod can be changed at the shift lever.

601432-10

TUNING THE CHASSIS

– – Remove screw 3 .

Position shift rod 2 in one of the drill holes Guideline A D . Mount and tighten screw 3 .

Screw, shift rod M6 12 Nm (8.9 lbf ft)

Loctite ® 243™ 50

601433-10 – Tighten nuts 1 .

Info

After the counter nuts have been tightened, the bearings of the shift shaft must be central and aligned identically to each other in order to ensure free dom of movement in the bearing shells.

601431-10 9.18

Adjusting the foot brake lever stub

– – Take off cap 1 .

Remove screw 2 with the foot brake lever stub.

601434-10 – Position the shift lever stub with the screw into drill hole on the desired lever length.

A , B , or C , depending 601435-10 – Tighten screw 2 .

Guideline Bolt, foot brake lever stub M6 – Mount cap 1 .

601434-10 10 Nm (7.4 lbf ft)

Loctite ® 243™

TUNING THE CHASSIS

9.19

Adjusting the foot brake lever

– – – Loosen lock nut 1 while holding heim joint 2 .

Adjust the foot brake lever using handwheel 3 .

Guideline Distance handwheel - heim joint A ≤ 10 mm ( ≤ 0.39 in) Tighten lock nut 1 while holding heim joint 2 .

51

101251-10 9.20

Handlebar height

By removing or inserting distance sleeve different positions.

1 , you can set the handlebar height to two Length, distance sleeve 15 mm (0.59 in) With distance sleeves, the handlebar stub is positioned low for sports use. Removing the distance sleeves gives a more upright sitting position.

Standard Low position with distance sleeve 601437-10 9.21

Adjusting the handlebar height Info

The handlebar stub position must be identical on the left and right of the vehicle.

Adjusting the high position of the handlebar stubs:

– Loosen screw 1 .

Info

Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub.

601438-10 – Remove screw 2 .

601439-10

TUNING THE CHASSIS 52

601437-11 601440-10 – – – – – Remove distance sleeve 3 .

All cables routed under the upper triple clamp must now be routed under the handlebar stub.

Push the handlebar stub carefully up to the upper triple clamp.

Position distance sleeve 3 above the triple clamp.

Mount and tighten screw 2 .

Guideline Remaining frame bolts M5 5 Nm (3.7 lbf ft) – – – Tighten screw 1 .

Guideline Screw, handlebar stub M8 20 Nm (14.8 lbf ft) Repeat the adjustments on the other handlebar stub.

Move the handlebar to and fro over the entire steering range.

» If the cables restrict the freedom of movement of the steering: – Correct the cable routing.

Adjusting the low position of the handlebar stubs:

– Loosen screw 1 .

Info

Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub.

601440-10 601437-12 – – – – Remove screw 2 with distance sleeve 3 .

Carefully shift the handlebar stub by the length of the distance sleeve.

Guideline Length, distance sleeve 15 mm (0.59 in) Lay all cables between the upper triple clamp and the handlebar stub.

Position distance sleeve 3 .

– Mount and tighten screw 2 .

Guideline Remaining frame bolts M5 5 Nm (3.7 lbf ft) 601439-10 601438-10 – – – Tighten screw Guideline 1 .

Screw, handlebar stub M8 20 Nm (14.8 lbf ft) Repeat the adjustments on the other handlebar stub.

Move the handlebar to and fro over the entire steering range.

» If the cables restrict the freedom of movement of the steering: – Correct the cable routing.

SERVICE WORK ON THE CHASSIS

10.1

Raising the rear of the motorcycle with lifting gear Note Danger of damage

  The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– – Insert the adapter into the lifting gear at the rear.

Adapter (61029055120) Rear wheel stand (61029055400) Stand the motorcycle upright, align the lifting gear to the link fork and the adapters, and raise the motorcycle.

53

601441-01 10.2

Removing the rear of motorcycle from the lifting gear Note Danger of damage

  The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– – Secure the motorcycle against falling over.

Remove the lift stand from the rear and lean the vehicle on the side stand.

10.3

Raising the front of the motorcycle with lifting gear Note Danger of damage

  The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

Preliminary work

Raise the rear of the motorcycle with lifting gear. ( p. 53)

Main work

– Move the handlebar to the straight-ahead position. Align the lifting gear at the front with the adapters to the fork legs.

Front wheel stand (61029055300) –

Info

Always raise the rear of the motorcycle first.

Raise the motorcycle at the front.

601442-01 10.4

Taking the motorcycle off of the front wheel stand Note Danger of damage

  The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– – Secure the motorcycle against falling over.

Remove the lifting gear from the front.

SERVICE WORK ON THE CHASSIS

10.5

Bleeding the fork legs Preliminary work

Raise the rear of the motorcycle with lifting gear. (

Main work

– Remove bleeder screws 1 briefly.

p. 53)

Any excess pressure escapes from the interior of the fork.

Mount and tighten bleeder screws.

Info

Perform this action on both fork legs.

601443-10 10.6

Removing the seat

– Unlock quick releases 1 and remove the seat.

54

10.7

Fitting the seat

601444-10 – – Position the seat with quick releases 1 .

Lock quick releases 1 .

601444-10 10.8

Removing the air filter

x

Note Engine failure

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

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

– –

Preliminary work

Remove the seat. (

– Remove the fuel tank.

p. 54)

x

(

Main work

– Remove screws 1 .

Take off the filter box top.

p. 57)

Slide back clamp 2 . Pull off the engine breather hose and take off the clamp.

Info

Watch out for the engine breather hose.

101248-10

SERVICE WORK ON THE CHASSIS

– – Remove air filter 3 .

Clean the air filter box.

10.9

Installing the air filter

x 101249-10

Main work

– Position air filter 1 .

101249-11 – – Position the filter box top with the engine breather hose. Mount clamp engine breather hose.

2 with the Tighten screws 3 .

101248-11

Subsequent work

– Install the fuel tank.

Fit the seat. ( p. 54)

x ( p. 58)

10.10

Cleaning the air filter

x

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Do not clean the air filter with fuel or petroleum.

101250-01 – –

Preliminary work

Remove the seat. (

p. 54)

– Remove the fuel tank.

x

( p. 57)

– Remove the air filter.

x

( p. 54)

Main work

– Tap to remove coarse dirt. Brush off the air filter with a soft brush.

Spray on cleaner and leave it on for 10 minutes.

Air filter cleaner ( p. 120)

Rinse the air filter from the inside to the outside with a gentle spray of water.

Shake off remaining water. Let the air filter dry.

Info

Do not use compressed air to dry the filter.

55

SERVICE WORK ON THE CHASSIS

– – – – – Thoroughly spray the dry air filter with filter oil.

Air filter oil ( p. 120)

Leave the filter oil on the filter for 20 minutes.

Clean the air filter box.

Check the distribution of the filter oil.

» If unoiled areas are visible: – Oil the air filter again.

Wipe off excess filter oil.

Info

Do not apply too much oil to the air filter.

Follow-up work

– Install the air filter.

– Install the fuel tank.

Fit the seat. (

x

p. 54)

x

(

(

p. 55)

p. 58)

10.11

Removing the left side cover

– – Unlock quick releases 1 .

Take off side cover 2 .

10.12

Installing the left side cover

101213-10 – – Position side cover 1 .

Lock quick releases 2 .

101213-11 10.13

Removing the right side cover

– – Unlock quick releases 1 .

Take off side cover 2 .

101214-10

56

SERVICE WORK ON THE CHASSIS

10.14

Installing the right side cover

– – Position side cover Lock quick releases 1 .

2 .

57

10.15

Removing the exhaust cover

101214-11

Preliminary work

Remove the right side cover. (

Remove the left side cover. ( p. 56) p. 56)

Main work

– Unlock quick release 1 .

– – Repeat the operation on the opposite side.

Detach the exhaust cover from radiator 2 and remove.

10.16

Installing the exhaust cover

101215-10

Main work

– Attach the exhaust cover to radiator – Lock quick release 2 .

– 1 and position at the rear.

Repeat the operation on the opposite side.

101215-11

Subsequent work

Install the left side cover. (

Install the right side cover. (

p. 56)

p. 57)

10.17

Removing the fuel tank

x

Danger Fire hazard

  Fuel is highly flammable.

– – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Preliminary work

Remove the seat. ( p. 54)

SERVICE WORK ON THE CHASSIS Main work

– Remove screws – 1 of the steering damper.

Remove the steering damper.

101243-10 – Remove screws 2 .

101244-10 – Clean and disconnect fuel hose connection 3 .

Info

Remaining fuel may run out of the fuel hose.

101245-10 – – Raise the front of the fuel tank.

Detach overflow hose 4 from the T-piece.

101246-10 – – – Raise the rear of the fuel tank.

Disconnect electric plug-in connector 5 of the fuel pump.

Take off the fuel tank.

101247-10 10.18

Installing the fuel tank

x

Danger Fire hazard

  Fuel is highly flammable.

– – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

58

SERVICE WORK ON THE CHASSIS 59 Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Main work

– Position the fuel tank.

– Connect electric plug-in connector 1 of the fuel pump.

101247-11 – – – Position the fuel tank and raise it at the front.

Connect overflow hose 2 .

Lower the front of the fuel tank.

101246-11 – Connect fuel hose connector 3 with the new O-ring.

101245-10 – Mount and tighten screws 4 .

Guideline Remaining chassis screws M6 10 Nm (7.4 lbf ft) 101244-11 101243-11 – – – Position the steering damper.

Mount and tighten screws 5 .

Guideline Remaining chassis screws Mount and tighten screw 6 .

Guideline Screw, steering damper fixing bracket on triple clamp

Subsequent work

Fit the seat. ( p. 54)

M8 M6 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™

SERVICE WORK ON THE CHASSIS

10.19

Checking the fuel overflow reservoir

– Check the fluid level in the fuel overflow reservoir.

» If there is fluid in the fuel overflow reservoir: –

Empty the fuel overflow reservoir. ( p. 60)

601453-10 10.20

Emptying the fuel overflow reservoir Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning Environmental hazard

  Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Preliminary work

Remove the left side cover. ( p. 56)

– –

Main work

– Remove screw – Open cover 2 1 .

and empty the fuel overflow reservoir.

Close cover 2 .

Position the fuel overflow reservoir. Mount and tighten screw 1 .

Guideline Remaining chassis screws M6 10 Nm (7.4 lbf ft) 601452-10

Follow-up work

Install the left side cover. ( p. 56)

10.21

Checking for chain dirt

– Check the chain for loose dirt.

» If the chain is very dirty: –

Clean the chain. ( p. 61)

400678-01

60

SERVICE WORK ON THE CHASSIS

10.22

Cleaning the chain Warning Danger of accidents

  Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

Warning Danger of accidents

  Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

61 Info

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

– – – – Clean the chain regularly.

Rinse off loose dirt with a soft jet of water.

Remove old grease remains with chain cleaner.

Chain cleaner ( p. 120)

After drying, apply chain spray.

Chain lube for road use ( p. 120)

400725-01 10.23

Checking the chain tension Warning Danger of accidents

  Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces sary.

700322-01

Preliminary work

Raise the rear of the motorcycle with lifting gear. ( p. 53)

Main work

– Shift into neutral.

– In the area in front of where the chain passes through the link fork, push the chain upward and measure chain tension A .

Info

The lower chain section different chain positions.

B must be taut.

Chain wear is not always even, so you should repeat this measurement at Chain tension 15… 20 mm (0.59… 0.79 in) » If the chain tension does not meet specifications: –

Adjust the chain tension. ( p. 62)

SERVICE WORK ON THE CHASSIS 62

10.24

Adjusting the chain tension Warning Danger of accidents

  Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces sary.

100709-10

Preliminary work

Raise the rear of the motorcycle with lifting gear. (

Check the chain tension. ( p. 61)

Remove the rear frame sliders. ( p. 71)

Guideline

p. 53)

Main work

– Loosen nut 1 .

– – Loosen nuts 2 .

Adjust the chain tension by turning adjusting screws 3 on the left and right.

Chain tension 15… 20 mm (0.59… 0.79 in) Turn adjusting screws 3 and right chain adjuster on the left and right so that the markings on the left 4 are in the same position in relation to the reference marks C . The rear wheel is then correctly aligned.

– – –

Info

The lower chain section must be taut.

Chain wear is not always even, so you should check the setting at different chain positions.

Tighten nuts 2 .

Make sure that chain adjusters 4 are in contact with adjusting screws 3 .

Tighten nut 1 .

Guideline Nut, rear wheel spindle M25x1.5

90 Nm (66.4 lbf ft) Thread greased

Info

The wide adjustment range of the chain adjuster (35 mm/1.38") allows dif ferent secondary transmission ratios to be used with the same chain length.

Chain adjusters 4 can be turned through 180°.

Subsequent work

Install the rear frame sliders. ( p. 71)

10.25

Checking the chain, rear sprocket and engine sprocket

– Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket.

x

Info

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

100132-10

SERVICE WORK ON THE CHASSIS

700303-01 – – – Shift into neutral.

Pull the lower chain section with specified weight A .

Guideline Weight, chain wear measurement 15 kg (33 lb.) Measure the distance B of 18 chain links in the lower chain section.

Info

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

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

x

Info

When the chain is replaced, the rear sprocket and engine sprocket should also be changed.

A new chain wears out faster on old, worn sprockets.

For safety reasons, the chain has no chain joint.

Check the chain sliding guard for wear at the opening.

» If the rivets 1 of the chain are no longer visible at the lower edge opening of the chain sliding guard: – Change the chain sliding guard.

x Check that the chain sliding guard is firmly seated.

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

Guideline Screw, chain sliding guard M5 5 Nm (3.7 lbf ft)

63

601456-10 10.26

Adjusting basic position of clutch lever

– 101224-10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw 1 .

Info

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

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

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any force.

Do not make any adjustments while riding!

SERVICE WORK ON THE CHASSIS

10.27

Checking fluid level of hydraulic clutch Info

The fluid level rises with increasing wear of the clutch lining disc.

Do not use brake fluid.

– – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

Check the fluid level.

The fluid level must be between the

MIN

and

MAX

markings.

» If the coolant level does not meet specifications: –

Correct the fluid level of the hydraulic clutch. ( p. 64)

64

601446-01 10.28

Correcting fluid level of hydraulic clutch Info

The fluid level rises with increasing wear of the clutch lining disc.

Do not use brake fluid.

– – – – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

Remove screw cap with membrane.

Correct the fuel level.

Guideline The fluid level must be between the

MIN

and

MAX

markings.

Hydraulic fluid (15) ( p. 119)

Refit the screw cap with the membrane.

601445-01

BRAKES 65

11.1

Checking the front brake discs Warning Danger of accidents

  Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be pleased to help.) – Check the thickness of the brake disc in several places to see if it is within the specified wear tolerance A .

Info

Wear reduces the thickness of the brake discs in area 1 of the brake discs.

100135-10 – Brake discs - wear limit Front 4.5 mm (0.177 in) » If the brake disc thickness is less than the specified value: – Change the brake discs.

x Check the brake discs for damage, cracking and deformation.

» If the brake discs exhibit damage, cracking or deformation: – Change the brake discs.

x 11.2

Checking the rear brake disc Warning Danger of accidents

  Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be pleased to help.) – Check the thickness of the brake disc in several places to see if it conforms to mea surement A .

Info

Wear reduces the thickness of the brake disc in area 1 of the brake disc.

400480-10 – Brake disc - wear limit Rear 4.5 mm (0.177 in) » If the brake disc thickness is less than the specified value: – Change the brake disc.

x Check the brake disc for damage, cracking and deformation.

» If damage, cracks or deformation are visible on the brake disc: – Change the brake disc.

x 11.3

Adjusting the basic position of the hand brake lever

– – Pull the brake lever forwards.

Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing wheel 1 .

Info

Do not make any adjustments while riding!

601447-10

BRAKES

11.4

Checking the front brake fluid level Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be pleased to help.)

Warning Danger of accidents

  Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be pleased to help.) – – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

Check the brake fluid level in the brake fluid reservoir 1 .

» If the brake fluid is below the

MIN

– Add front brake fluid.

x (

marking:

p. 66)

66

601448-10 11.5

Adding brake fluid of front brake

x

Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be pleased to help.) – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of children.

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning Danger of accidents

  Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be pleased to help.)

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

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

Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces.

Use only clean brake fluid from a sealed container!

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

Loosen screw.

Remove cap 1 with membrane 2 .

Add brake fluid to the

MAX

level.

Brake fluid DOT 4 / DOT 5.1 ( p. 118)

Position the cap with the membrane. Mount and tighten the screws.

601449-10

BRAKES Info

Clean up overflowed or spilt brake fluid immediately with water.

11.6

Checking the front brake linings Warning Danger of accidents

  Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be pleased to help.)

Note Danger of accidents

  Reduced braking efficiency caused by damaged brake discs.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.

– – Check all brake linings on both brake calipers to ensure they have minimum thick ness A .

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

x Check all brake linings on both brake calipers for damage and cracking.

» If damage or wear is encountered: – Change the front brake linings.

x 100715-10 11.7

Checking the rear brake fluid level Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be pleased to help.)

Warning Danger of accidents

  Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be pleased to help.) – – Stand the vehicle upright.

Check the brake fluid level of the brake fluid reservoir.

» If the fluid level reaches the – Add rear brake fluid.

x (

MIN

mark

p. 67)

1 :

67

601450-10 11.8

Adding rear brake fluid

x

Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be pleased to help.) – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of children.

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

BRAKES Warning Danger of accidents

  Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be pleased to help.)

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

68 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 is corrosive and will damage painted surfaces.

Use only clean brake fluid from a sealed container!

– – – – Stand the vehicle upright.

Remove screw cap 1 with membrane Add brake fluid to the

MAX

level.

2 .

Brake fluid DOT 4 / DOT 5.1 ( p. 118)

Refit screw with membrane.

Info

Clean up overflowed or spilt brake fluid immediately with water.

601451-10 11.9

Checking the rear brake linings Warning Danger of accidents

  Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be pleased to help.)

Note Danger of accidents

  Reduced braking efficiency caused by damaged brake discs.

– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.

– – Check the brake linings for minimum thickness A .

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

x Check the brake linings for damage and cracking.

» If damage or wear is encountered: – Change the rear brake linings.

x 101242-10

WHEELS, TIRES

12.1

Removing the front frame sliders

– – – Remove screw 1 .

Take off frame slider 2 .

Pull the second frame slider with the linkage arm out of the wheel spindle.

69

101238-10 12.2

Installing the front frame sliders

– – – Position the frame slider with the linkage arm in the wheel spindle.

Mount frame slider 1 on the linkage arm.

Mount and tighten screw 2 .

Guideline Remaining chassis screws M6 10 Nm (7.4 lbf ft) 12.3

Removing the front wheel

x 101238-11

Preliminary work

Raise the rear of the motorcycle with lifting gear. ( p. 53)

– –

Raise the front of the motorcycle with lifting gear. (

Remove the front frame sliders. ( p. 69)

p. 53)

Main work

– Remove screws – 1 them to one side.

from both brake calipers.

Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc. Pull the brake calipers carefully back from the brake discs and hang

Info

Do not pull the hand brake lever when the brake calipers are removed.

101239-10 101240-10 – – – – Loosen screws 2 and 3 .

Unscrew screw 2 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw 2 .

Warning Danger of accidents

  Reduced braking efficiency due to damaged brake discs.

– Always lay down the wheel in such a way that the brake discs are not damaged.

Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

Remove spacers 4 .

100779-10

WHEELS, TIRES

12.4

Installing the front wheel

x

70

Main work

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn: – Replace the wheel bearing.

Clean and grease the shaft seal rings x 1 and mating surfaces A of the spacers.

Long-life grease ( p. 120)

100781-10 – Insert the wide spacer on the left-hand side travel).

2 (when looking in the direction of

Info

The arrow B indicates the direction of rotation of the front wheel.

– Insert the narrow spacer on the right-hand side (when viewed in the direction of travel).

100780-10 101241-10 101239-11 – – – – – – – – – – – –

Warning Danger of accidents

  Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Clean screw 3 and axle 4 .

Lift the front wheel into the fork, position it, and insert the wheel spindle.

Mount and tighten screw 3 .

Guideline Bolt, front axle M25x1.5

45 Nm (33.2 lbf ft) Position the brake calipers and check that the brake linings are seated correctly.

Mount screws 5 on both brake calipers but do not tighten yet.

Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in its engaged position.

The brake calipers straighten.

Tighten screws 5 on both brake calipers.

Guideline Screw, front brake caliper M10x1.25

45 Nm (33.2 lbf ft)

Loctite ® 243™

Remove the fixation of the hand brake lever.

Take the motorcycle off of the front wheel stand. ( p. 53) Remove the rear of the motorcycle from the lifting gear. ( p. 53)

Pull the front brake and compress the fork powerfully a few times.

The fork legs straighten.

Tighten screws 6 .

Guideline Fork end pinch bolts M8 15 Nm (11.1 lbf ft) 101264-10

Subsequent work

Install the front frame sliders. ( p. 69)

WHEELS, TIRES

12.5

Removing the rear frame sliders

– – – Remove screw 1 .

Take off frame slider 2 .

Pull the second frame slider with the linkage arm out of the wheel spindle.

71

101263-10 12.6

Installing the rear frame sliders

– – – Position the frame slider with the linkage arm in the wheel spindle.

Mount frame slider 1 on the linkage arm.

Mount and tighten screw 2 .

Guideline Remaining chassis screws M6 10 Nm (7.4 lbf ft) 12.7

Removing the rear wheel

x 101263-11

Preliminary work

Raise the rear of the motorcycle with lifting gear. (

Remove the rear frame sliders. ( p. 71)

Main work

– Remove nut – 1 .

Remove chain adjuster – Remove axle 3 .

2 .

p. 53)

100722-10 100723-01 – – Push the rear wheel as far forward as possible and then remove the chain from the rear sprocket.

Warning Danger of accidents

  Reduced braking efficiency due to damaged brake discs.

– Always lay down the wheel in such a way that the brake discs are not damaged.

Take the rear wheel out of the swingarm carefully without damaging the rim or brake disc.

Info

Do not operate the foot brake when the rear wheel is removed.

WHEELS, TIRES 72

12.8

Installing the rear wheel

x

Warning Danger of accidents

  Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning Danger of accidents

  No braking effect when operating the rear brake.

– After installing the rear wheel, always operate the foot brake until the pressure point is reached.

100724-10 – – – – – – – – – –

Preliminary work

Raise the rear of the motorcycle with lifting gear. (

Remove the rear frame sliders. ( p. 71)

Remove the rear wheel.

x (

Check the rear hub cush drive.

p. 71)

x

( p. 73)

Main work

– Remove bushing seal ring.

p. 53)

1 . Clean and grease the mating surfaces of the bushing and shaft

Long-life grease ( p. 120)

Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn: – Replace the wheel bearing.

x Install the bushing.

Clean the thread of the axle and nut.

Clean the mating surfaces of the brake caliper frame and swingarm.

Push the brake caliper frame 2 completely to the rear.

Position the rear wheel, and position the brake caliper support between the rim and the brake disc.

Position the brake caliper on the brake disc.

Position the rear wheel on the bearing surfaces in the swingarm.

100725-10 – – Push the rear wheel as far forward as possible and place the chain on the rear sprocket.

Pull the rear wheel back and insert the axle.

100726-01 100727-10 – – – Place chain adjuster Tighten nut 5 .

3 Position chain adjuster on the tensioning screw.

4 and place it on the tensioning screw.

Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to reference marks A .

Nut, rear wheel spindle M25x1.5

90 Nm (66.4 lbf ft) Thread greased – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

Subsequent work

Remove the rear of the motorcycle from the lifting gear. (

Check the chain tension. ( p. 61)

p. 53)

WHEELS, TIRES

Install the rear frame sliders. ( p. 71)

12.9

Checking rear hub cush drive

x

Info

The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out during operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged.

100728-01 –

Preliminary work

Raise the rear of the motorcycle with lifting gear. (

Remove the rear frame sliders. ( p. 71)

– – Remove the rear wheel.

x (

Main work

– Remove the rear sprocket carrier.

p. 71)

Check the rear hub for damage and wear.

» If the rear hub cush drive is damaged or worn: – Change the shock absorber.

x Position the rear sprocket carrier.

p. 53)

Info

A set of bolts and shock absorbers should have as little free travel as possi ble to increase the service life of the shock absorbers.

– – –

Subsequent work

– Install the rear wheel.

x ( p. 72)

Remove the rear of the motorcycle from the lifting gear. (

Check the chain tension. ( p. 61)

Install the rear frame sliders. ( p. 71)

p. 53)

12.10

Checking the tire condition Warning Danger of accidents

  Uncontrollable vehicle handling in the event of a flat tire.

– In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be pleased to help.)

Warning Danger of crashing

  Poor vehicle handling due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning Danger of accidents

  Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.

– Only tires/wheels approved by KTM and with the corresponding speed index should be used.

73 Info

The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcycle.

– – – Check the front and rear tires for cuts, run-in objects, and other damage.

» If the tires exhibit cuts, run-in objects, or other damage: – Change the tires.

Check the tread.

» If the tread is worn: – Change the tires.

Check the age of the tires.

400602-10

WHEELS, TIRES 74 Info

The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the ture.

at the latest after five years.

DOT

marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufac KTM recommends that the tires are changed regardless of the actual wear, » If a tire is more than five years old: – Change the tires.

12.11

Checking the tire pressure Info

Low tire pressure leads to abnormal wear and overheating of the tire.

Correct tire pressure ensures riding comfort and maximum tire life.

400695-01 – – – Remove the dust cap.

Check the tire pressure when the tires are cold.

Tire air pressure Front Rear 2.0 bar (29 psi) 1.5 bar (22 psi) » If the tire pressure does not meet specifications: – Correct the tire pressure.

Mount the dust cap.

Info

The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is faulty.

ELECTRICAL SYSTEM

13.1

Removing the battery

x – – – – –

Warning Risk of injury

  Battery acid and battery gases cause serious chemical burns.

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.

In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.

Caution Danger of accidents

  If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.

– Never operate the vehicle with a discharged battery or without a battery.

Preliminary work

– Switch off all power consumers and the engine.

Remove the seat. ( p. 54)

Main work

– Disconnect negative (minus) cable 1 of the battery.

75

101230-10 – – Remove the cover of the positive terminal.

Disconnect the positive (plus) cable 2 of the battery.

101231-10 – – – Remove screws 3 .

Removing the securing bracket 4 .

Pull the battery up and out of the battery rack.

101232-10

ELECTRICAL SYSTEM

13.2

Installing the battery

x

Main work

– Position the battery in the battery rack.

Info

The terminals of the battery must face the rear of the vehicle.

– Position the bracket 1 .

101233-10 – – – Mount and tighten screws 2 .

Guideline Remaining chassis screws M6 Reconnect the positive (plus) 3 cable of the battery.

Position cover of the positive terminal.

10 Nm (7.4 lbf ft)

76

101234-10 – Reconnect the negative (minus) cable 4 of the battery.

101230-11

Subsequent work

Fit the seat. (

p. 54)

Set the clock with

SET CLOCK

. ( p. 31)

13.3

Recharging the battery

x – – – – –

Warning Risk of injury

  Battery acid and battery gases cause serious chemical burns.

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.

In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.

Warning Environmental hazard

  The battery contains elements that are harmful to the environment.

– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.

Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

ELECTRICAL SYSTEM Info

Even when there is no load on the battery, it discharges steadily.

The charge state and the type of charge are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the battery's service life.

If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

Preliminary work

– Switch off all power consumers and switch off the engine.

Remove the seat. ( p. 54)

– Disconnect the negative (minus) cable of the battery to avoid damage to the motor cycle's electronics.

Main work

– Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

Info

Never remove lid Charge the battery at no more than 10% of the capacity specified on the battery housing 2 1 .

.

– Switch off the charger after charging. Reconnect the battery.

Guideline The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the motorcycle is not in use 3 months

77

100151-10

Subsequent work

Fit the seat. (

p. 54)

Set the clock with

SET CLOCK

. ( p. 31)

13.4

Changing the main fuse Warning Fire hazard

  The electrical system can be overloaded if the wrong fuses are used.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Info

The main fuse protects all power consumers of the vehicle. The main fuse is under the seat.

Preliminary work

– Switch off all power consumers and the engine.

Remove the seat. ( p. 54)

ELECTRICAL SYSTEM Main work

– Remove protection covers – 1 Remove the faulty main fuse .

2 .

Info

A reserve fuse 3 is located in the starter relay.

– Install a new main fuse.

Fuse (58011109130) ( p. 99)

Tip

Place the spare fuse in the starter relay so that it is available if needed.

Attach the protection covers 1 .

78

101226-10

Follow-up work

Fit the seat. (

p. 54)

Set the clock with

SET CLOCK

. ( p. 31)

13.5

Changing the fuses of individual power consumers Warning Fire hazard

  The electrical system can be overloaded if the wrong fuses are used.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Info

The fuse box containing the fuses of individual power consumers is located under the seat.

Preliminary work

– Switch off all power consumers and switch off the engine.

Remove the seat. ( p. 54)

Main work

– Open the fuse box cover 1 .

101228-10 101229-10 – – Check the fuses.

Info

A defective fuse is shown by a burned-out fuse wire A .

Remove the defective fuse.

Guideline Fuse tive)

1

- 10 A - emergency OFF switch, combination instrument (permanent posi Fuse

2

- 10 A - ignition, fuel injection, combination instrument (accessories con nected to the emergency OFF switch) Fuse

3

- 10 A - fuel pump Fuse

4

- 5 A - quick shifter Fuse

res.

- 10 A - spare fuses

ELECTRICAL SYSTEM

– Use spare fuses with the correct rating only.

Fuse (58011109110) ( Fuse (58011109105) ( p. 99) p. 99)

Tip

Replace the spare fuse in the fuse box so that it is available if needed.

– Close the fuse box cover.

Follow-up work

Fit the seat. ( p. 54)

79

COOLING SYSTEM

14.1

Cooling system 80

The water pump with a 3D water pump wheel tion of the coolant. The heat exchanger enables faster warming of the engine oil at the start of a journey and better heat dissipation for the engine oil during the journey.

The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap 2 pensating tank . The heat expansion causes the surplus coolant to flow into the com 3 1 in the engine ensures forced circula . When the temperature falls, this surplus coolant is sucked back into the cooling system.

400415-10 Cooling takes place by means of the air stream and a radiator fan 4 , which is con trolled by a thermoswitch.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool ing effect.

401167-10 14.2

Checking the coolant level Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

101225-01

Condition

The engine is cold.

The radiator is completely full.

– Rest the motorcycle on its side stand on a horizontal surface.

– Check the coolant level in the compensating tank.

The coolant level must be between

MIN

and

MAX

.

» If there is no coolant in the compensating tank: – Check the cooling system for leaks.

x

Info

Do not operate the motorcycle!

– Add coolant/bleed the cooling system.

x ( p. 81)

» If the coolant level in the compensating tank does not meet specifications, but the tank is not empty: – – Check the cooling system for leaks.

x

Fill the cooling system compensating tank. ( p. 80)

14.3

Filling cooling system compensating tank Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning Danger of poisoning

  Coolant is poisonous and a health hazard.

– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

COOLING SYSTEM Note Engine damage

  Impaired cooling efficiency due to air trapped in the cooling system.

– After draining coolant and refilling the cooling system, the motorcycle must be raised at the front according to the model type.

This is the only way of ensuring that the cooling system is filled without air bubbles. (Your authorized KTM workshop will be pleased to help.) 101225-10 – – – –

Check the coolant level. ( p. 80)

Remove the cap 1 of the compensating tank.

Add coolant to the specified level.

Guideline The coolant level must be between

MIN

and

MAX

.

Alternative 1

Coolant ( p. 118)

Alternative 2

Coolant (mixed ready to use) ( p. 118)

Mount the cap of the compensating tank.

14.4

Adding coolant/bleeding the cooling system

x

Warning Danger of poisoning

  Coolant is poisonous and a health hazard.

– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition

The side cover has been removed.

– Position the vehicle as shown and secure it against rolling. Height difference must be reached.

A Guideline Height difference A 50 cm (19.7 in)

81

400494-10 – Remove radiator cap 1 and bleeder screw 2 of the radiator.

101235-10

COOLING SYSTEM 82

– – – Remove bleeder screws 3 of the cylinder heads.

Add coolant until it exits from the vent hole without bubbles.

Coolant 2.60 l (2.75 qt.)

Coolant ( p. 118)

Coolant (mixed ready to use)

( p. 118)

Mount and tighten the bleeder screws with the seal rings.

Guideline Remaining engine screws Remaining chassis screws M6 M6 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 101236-10 – – – – – Completely fill the radiator with coolant and close it with radiator cap 1 .

Position the vehicle on a level surface.

Remove the cap of the compensating tank.

Add coolant to the compensating tank until the coolant reaches the specified level.

Guideline The coolant level must be between

MIN

and

MAX

.

Mount the cap of the compensating tank.

101237-10

TUNING THE ENGINE

15.1

Checking the play in the throttle cable

400192-10 – – Check the throttle grip for smooth operation.

Move the handlebar to the straight-ahead position. Move the throttle grip back wards and forwards to ascertain the play in the throttle cable.

Throttle cable play 3… 5 mm (0.12… 0.2 in) » If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable.

x

( p. 83)

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

– Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.

The idle speed must not change.

» If the idle speed changes: – Adjust the play in the throttle cable.

x

( p. 83)

15.2

Adjusting the play in the throttle cable

x – – 101223-10 – – – – – Move the handlebar to the straight-ahead position.

Throttle position sensor circuit A - check in zero position.

x

Info

It is imperative to use the KTM diagnostics tool for this.

Push back protective cover 1 .

Loosen lock nut 2 .

Set the play in the throttle cable by turning adjusting screw 3 .

Guideline Throttle cable play 3… 5 mm (0.12… 0.2 in) Tighten lock nut 2 .

Mount protection cap 1 .

15.3

Quick shifter

The quick shifter 1 is mounted on the left of the engine.

83

601458-10 The quick shifter control unit 2 is mounted below the seat.

601459-10

TUNING THE ENGINE Possible states

A I x B C y II D 401212-10 Shift lever in neutral position Ignition circuit is interrupted – Green LED goes out, red LED lights up Ignition interruption until shift begin – Range should be as small as possible but must not overlap Shift process in transmission begins – Resistance in shift lever increases Shift process in transmission ended – Resistance in shift lever decreases Shift end until ignition circuit closed – Range should be as small as possible but must not overlap Ignition circuit is closed – Red LED goes out, green LED lights up Shift lever at end stop 601414-10 With the quick shifter, it is not necessary to activate the clutch when upshifting gears from the 1st to the 6th gear.

The ignition is briefly interrupted by the control unit during a shift procedure.

To simplify adjustment of the quick shifter, it is equipped with two LEDs.

The green LED lights up when the ignition is not interrupted.

The red LED lights up when the ignition is interrupted.

The time span of the ignition interruption must be matched to the vehicle.

Info

It is always possible to shift by conventional means using the clutch and throt tle.

15.4

Checking/tuning the position of the quick shifter

x

Info

The quick shifter only operates when upshifting gears from 1st to 6th gear.

If the ignition circuit is interrupted too late, upshifting under full throttle is difficult or not possible at all. If it is interrupted to early, the ignition circuit may be interrupted unintentionally (e. g. due to shift lever vibrations).

If the ignition circuit is closed too early, the shift procedure in the transmission cannot be completed correctly.

84

TUNING THE ENGINE

– Check the installation position of the quick shifter.

Guideline Distance S 7… 8 mm (0.28… 0.31 in) » If the specifications have not been met: –

Position the quick shifter. ( p. 86)

601457-10

85

– – – – 401213-10 Switch on the ignition by pressing the emergency OFF switch into the position .

Switch on the quick shifter. To do so, flip the quick shifter switch up to the

EIN

position.

Engage 3rd or 4th gear.

The green LED lights up on the quick shifter.

Check the quick shifter against the overview. Turn the rear wheel slightly while doing so.

A - Shift lever in neutral position

I

- Ignition circuit is interrupted Green LED goes out; red LED lights up (must lie between and B ) A

x

- Ignition interruption until shift begin B - Shift process in transmission begins C - Shift process in transmission ended Range should be as small as possible but must not overlap Resistance in shift lever increases Resistance in shift lever decreases Range should be as small as possible but must not overlap

y

- Shift end until ignition circuit closed

II

- Ignition circuit is closed Red LED goes out; green LED lights up (must lie between and D ) C D - Shift lever at end stop » The LED display is not as specified: – Adjust the settings.

Info

Turning screw

I

Turning screw

II

clockwise causes the ignition circuit to be interrupted earlier.

clockwise causes the ignition circuit to close earlier.

TUNING THE ENGINE

15.5

Positioning the quick shifter Main work

– Release nuts – Remove screw 1 while holding quick shifter 3 .

2 with your hand.

601471-10 – – – – Turn heim joint 4 until distance S is reached.

Guideline Distance S 7… 8 mm (0.28… 0.31 in) Check distance T .

Guideline Distance T ≤ 15 mm ( ≤ 0.59 in) Mount and tighten screw 3 .

Guideline Remaining frame bolts M5 5 Nm (3.7 lbf ft) Check distance S again.

Guideline Distance S » If the specifications have not been met: – Repeat the steps.

7… 8 mm (0.28… 0.31 in) 101271-10 – Tighten nut 1 while holding quick shifter 2 with your hand.

86

101272-10

Subsequent work

– Check and tune the setting of the quick shifter.

x

( p. 84)

SERVICE WORK ON THE ENGINE

16.1

Checking the engine oil level Info

The engine oil level must be checked at normal engine operating temperature.

Preliminary work

– Stand the motorcycle upright on a horizontal surface.

Remove the left side cover. ( p. 56)

Main work

– Remove screw 1 .

101216-10 – Insert the provided oil dipstick 2 all the way - do not screw in.

Oil dipstick (60030020100)

Info

After switching off the engine, wait one minute before checking the level.

Do not screw in the oil dipstick; only insert it to the stop.

101217-10 The engine oil level must be within range A on the oil dipstick.

» If the engine oil level is not at the specified level: –

Add engine oil. ( p. 90)

– Mount screw 1 .

Subsequent work

Install the left side cover. ( p. 56)

16.2

Changing engine oil and filter, cleaning oil screen

x – – Drain the engine oil and clean the oil screens.

Fill up with engine oil.

x ( p. 89)

x

( p. 87)

500281-01 16.3

Draining engine oil, cleaning oil screens

x

Warning Danger of scalding

  Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Drain the engine oil only when the engine is warm.

87

SERVICE WORK ON THE ENGINE Preliminary work

Remove the left side cover. (

Remove the right side cover. (

Remove the exhaust cover. (

p. 56) p. 56)

p. 57)

– –

Main work

– Park the motorcycle on a level surface.

– Place a suitable container under the engine.

– Remove oil drain plug Remove the oil filter.

x 1

(

with the magnet, O-rings, and oil screen.

p. 88)

Completely drain the engine oil.

101219-10 – Thoroughly clean magnet 2 and oil screen 3 of the oil drain plug.

88

700292-11 – – Mount and tighten the oil drain plugs with the magnet, O-rings, and oil screen.

Guideline Oil drain plug M20x1.5

20 Nm (14.8 lbf ft) Install the oil filter.

x ( p. 89)

101219-11

Follow-up work

Install the exhaust cover. (

Install the right side cover. (

Install the left side cover. (

p. 57) p. 57)

p. 56)

16.4

Removing the oil filter

x

Warning Danger of scalding

  Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Preliminary work

– Place a suitable container under the engine.

Main work

– Remove screws 1 . Take off oil filter cover 2 with the O-ring.

101220-10

SERVICE WORK ON THE ENGINE

– – – Pull oil filter 3 out of the oil filter housing.

Circlip pliers reverse (51012011000) Completely drain the engine oil.

Clean the parts and the sealing area thoroughly.

16.5

Installing the oil filter

x 101221-10 – – – Insert oil filter 1 .

Lubricate the O-ring of the oil filter cover. Mount oil filter cover 2 .

Mount and tighten the screws.

Guideline Remaining engine screws M5 6 Nm (4.4 lbf ft) 101222-10 16.6

Filling up with engine oil

x

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

101216-10 – –

Main work

– The oil must be added in two steps.

Engine oil 3.60 l (3.8 qt.) – – External tem perature: ≥ 0 °C ( ≥ 32 °F) External tem perature: < 0 °C (< 32 °F) Engine oil (SAE 10W/50)

( p. 118)

Engine oil (SAE 5W/40)

( p. 118)

Remove screw 1 and add engine oil.

Engine oil (1st quantity) 3.00 l (3.17 qt.) External tem perature: ≥ 0 °C ( ≥ 32 °F) External tem perature: < 0 °C (< 32 °F) Engine oil (SAE 10W/50)

( p. 118)

Engine oil (SAE 5W/40)

( p. 118)

Mount screw 1 .

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Start the engine and check that it is oil-tight.

Remove screw 1 and pour in the remaining engine oil.

Engine oil (2nd quantity) 0.60 l (0.63 qt.) External tem perature: ≥ 0 °C ( ≥ 32 °F) External tem perature: < 0 °C (< 32 °F) Engine oil (SAE 10W/50)

( p. 118)

Engine oil (SAE 5W/40)

( p. 118)

89

SERVICE WORK ON THE ENGINE

– Mount screw 1 .

Danger Danger of poisoning

–   Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

– Start the engine and check that it is oil-tight.

Subsequent work

Check the engine oil level. (

Install the left side cover. (

p. 87)

p. 56)

16.7

Adding engine oil Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

101216-10

Preliminary work

– Stand the motorcycle upright on a horizontal surface.

Remove the left side cover. ( p. 56)

Check the engine oil level. ( p. 87)

Main work

– Remove screw 1 and add engine oil.

Condition

External temperature: ≥ 0 °C ( ≥ 32 °F)

Engine oil (SAE 10W/50) ( p. 118)

Condition

External temperature: < 0 °C (< 32 °F)

Engine oil (SAE 5W/40) ( p. 118)

Info

For optimal performance of the engine oil, do not mix different types of engine oil.

If appropriate, change the engine oil.

– Mount screw 1 .

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

– Start the engine and check that it is oil-tight.

Subsequent work

Check the engine oil level. ( p. 87)

Install the left side cover. ( p. 56)

90

CLEANING, CARE

17.1

Cleaning the motorcycle Note Material damage

  Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

91 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 the exhaust system to keep water from entering.

Remove loose dirt first with a soft jet of water.

Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush.

Motorcycle cleaner ( p. 120)

– – – – –

Info

Clean the vehicle with warm water containing normal motorcycle cleaner and a soft sponge.

After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.

Warning Danger of accidents

  Reduced braking efficiency due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

The heat causes water to evaporate from inaccessible parts of the engine and brakes.

After the motorcycle has cooled off, lubricate all moving parts and bearings.

Clean the chain. ( p. 61)

Treat all painted parts with a mild paint care product.

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic

surfaces ( p. 120)

17.2

Storage Info

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

401058-01 – – – – – – – – Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.

Clean the motorcycle. ( p. 91)

Change the engine oil and filter, clean the oil screen.

Check the coolant level. ( p. 80)

x ( p. 87)

Check the antifreeze.

x

Check the tire pressure. (

Remove the battery.

x

Recharge the battery.

x

(

(

p. 74)

p. 75)

p. 76)

CLEANING, CARE 92

– – – Guideline Storage temperature of battery without direct sunshine.

– perature.

0… 35 °C (32… 95 °F) Store the vehicle in a dry location that is not subject to large fluctuations in tem-

Info

KTM recommends raising the motorcycle.

Raise the rear of the motorcycle with lifting gear. ( Raise the front of the motorcycle with lifting gear. (

Cover the motorcycle with a porous sheet or blanket.

p. 53) p. 53)

Info

Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

17.3

Preparing for use after storage

401059-01 – – – – – – –

Take the motorcycle off of the front wheel stand. ( p. 53)

Recharge the battery.

x ( p. 76)

Install the battery.

Set the clock with

x ( p. 76)

SET CLOCK

. ( p. 31)

Fill up with fuel. ( p. 40)

Perform checks and maintenance measures when preparing for use. (

Take a test ride.

p. 39)

ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) Error level condition

09

EFI

warning lamp (

MIL

) flashes 9x short Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high

Blink code EFI warning lamp (MIL) Error level condition

13

EFI

warning lamp (

MIL

) flashes 1x long, 3x short Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high

Blink code EFI warning lamp (MIL) Error level condition

12

EFI

warning lamp (

MIL

) flashes 1x long, 2x short Engine coolant temperature sensor - input signal too low Engine coolant temperature sensor - input signal too high

Blink code EFI warning lamp (MIL) Error level condition

06

EFI

warning lamp (

MIL

) flashes 6x short Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high

Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition

33

EFI

warning lamp (

MIL

) flashes 3x long, 3x short Injector cylinder 1 - circuit fault 34

EFI

warning lamp (

MIL

) flashes 3x long, 4x short Injector cylinder 2 - circuit fault 07

EFI

warning lamp (

MIL

) flashes 7x short Throttle position sensor circuit B - input signal too low Throttle position sensor circuit B - input signal too high

Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition

02

EFI

warning lamp (

MIL

) flashes 2x short Crankshaft position sensor - circuit fault 37

EFI

warning lamp (

MIL

) flashes 3x long, 7x short Ignition coil 1, cylinder 1 - circuit fault 38

EFI

warning lamp (

MIL

) flashes 3x long, 8x short Ignition coil 1, cylinder 2 - circuit fault 49

EFI

warning lamp (

MIL

) flashes 4x long, 9x short Motor drive circuit A - circuit fault

93

ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition

24

EFI

warning lamp (

MIL

) flashes 2x long, 4x short Power supply - circuit fault 50

EFI

warning lamp (

MIL

) flashes 5x long Motor drive circuit B - circuit fault 68

EFI

warning lamp (

MIL

) flashes 6x long, 8x short Manifold absolute pressure sensor cylinder 1 - connection leaks 69

EFI

warning lamp (

MIL

) flashes 6x long, 9x short Manifold absolute pressure sensor cylinder 2 - connection leaks 14

EFI

warning lamp (

MIL

) flashes 1x long, 4x short Ambient air pressure sensor - input signal too low Ambient air pressure sensor - input signal too high

Blink code EFI warning lamp (MIL) Error level condition

41

EFI

warning lamp (

MIL

) flashes 4x long, 1x short Fuel pump control - short circuit to ground or open circuit Fuel pump control - input signal too high

Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition

25

EFI

warning lamp (

MIL

) flashes 2x long, 5x short Side stand switch - circuit fault 15

EFI

warning lamp (

MIL

) flashes 1x long, 5x short Rollover sensor - input signal too low Rollover sensor - input signal too high

Blink code EFI warning lamp (MIL) Error level condition Blink code EFI warning lamp (MIL) Error level condition

81

EFI

warning lamp (

MIL

) flashes 8x long, 1x short Immobilizer control unit - circuit fault 11

EFI

warning lamp (

MIL

) flashes 1x long, 1x short Manifold absolute pressure sensor cylinder 2 - input signal too low Manifold absolute pressure sensor cylinder 2 - input signal too high

Blink code EFI warning lamp (MIL) Error level condition

91

EFI

warning lamp (

MIL

) flashes 9x long, 1x short CAN bus communication error

94

TECHNICAL DATA - ENGINE

Design Displacement Stroke Bore Compression ratio Control Valve - valve stem diameter Intake Exhaust Valve clearance Exhaust at: 20 °C (68 °F) Intake at: 20 °C (68 °F) Crankshaft bearing Conrod bearing Piston pin bearing Piston Piston ring Engine lubrication Primary transmission Clutch Transmission Transmission ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Mixture preparation Ignition system Alternator Spark plug Electrode gap, spark plug Cooling Cold start device 19.1

Capacity - engine oil

Engine oil 3.60 l (3.8 qt.)

95

2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled 1,195 cm³ (72.92 cu in) 69 mm (2.72 in) 105 mm (4.13 in) 13.5:1 DOHC, 4 valves per cylinder, chain-driven 42 mm (1.65 in) 34 mm (1.34 in) 0.25… 0.30 mm (0.0098… 0.0118 in) 0.10… 0.15 mm (0.0039… 0.0059 in) Sleeve bearing Sleeve bearing No bearing bushes - DLC-coated piston pins Forged light alloy 1 upper compression (rectangular) ring, 1 lower compression ring, 1 oil scraper ring Dry sump lubrication system with three rotor pumps 40:76 Multi-disc clutch in oilbath / hydraulically operated 6-speed claw gears 14:36 16:30 20:30 21:27 23:26 25:26 Electronically controlled fuel injection Contactless controlled fully electronic ignition with digital igni tion adjustment 12 V, 390 W NGK LKAR9BI9 0.8… 0.9 mm (0.031… 0.035 in) Water cooling, permanent circulation of coolant by water pump Electric starter External temperature: ( ≥ 32 °F) ≥ 0 °C External temperature: < 0 °C (< 32 °F) Engine oil (SAE 10W/50)

( p. 118)

Engine oil (SAE 5W/40)

( p. 118)

TECHNICAL DATA - ENGINE

19.2

Capacity - coolant

Coolant 2.60 l (2.75 qt.)

Coolant ( p. 118) Coolant (mixed ready to use) ( p. 118)

96

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Hose clip, intake flange Remaining engine screws Screw, bearing retainer Screw, gear sensor Screw, pulse generator Camshaft drive sprocket bolt Freewheel ring bolt Nut, cylinder head Plug, vacuum connection Remaining engine screws Screw, camshaft bearing support Screw, clutch cover Screw, clutch spring Screw, coolant connection on cylinder head Screw, engine case Screw, engine case Screw, engine case Screw, freewheel holder Screw, locking lever Screw, oil pump cover Screw, shift drum locating Screw, shift lever Screw, starter motor Screw, stator Screw, valve cover Screw, water pump cover Screw, water pump wheel Stud, chain shaft Vacuum connection Oil jet Plug, crankshaft retainer Screw, camshaft bearing support M4 M5 M5 M5 M5 M6 M6 – 10.9

M6 M6 M6 M6 – 10.9

M6 M6 M6 M6x60 M6x80 M6x90 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6x0.75

M8 M8 – 10.9

Screw, camshaft bearing support Screw, engine case Screw, engine console Screw, heat exchanger Screw, timing chain guide rail Screw, timing chain tensioning rail Stud, exhaust flange Oil pressure sensor Plug, cam lever axis Plug, clutch lubrication M8 – 10.9

M8 M8 M8 M8 M8 M8 M10x1 M10x1 M10x1 1.5 Nm (1.11 lbf ft) 6 Nm (4.4 lbf ft) 6 Nm (4.4 lbf ft) 3 Nm (2.2 lbf ft) 6 Nm (4.4 lbf ft) 13 Nm (9.6 lbf ft) 15 Nm (11.1 lbf ft) 9 Nm (6.6 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) 12 Nm (8.9 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) 10 Nm (7.4 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) 10 Nm (7.4 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) 8 Nm (5.9 lbf ft) 2.5 Nm (1.84 lbf ft) 4 Nm (3 lbf ft) 15 Nm (11.1 lbf ft) Step 1 10 Nm (7.4 lbf ft) Step 2 18 Nm (13.3 lbf ft) Step 1 8.5 Nm (6.27 lbf ft) Step 2 14.5 Nm (10.7 lbf ft) 18 Nm (13.3 lbf ft) 20 Nm (14.8 lbf ft) 15 Nm (11.1 lbf ft) 15 Nm (11.1 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 15 Nm (11.1 lbf ft) 12 Nm (8.9 lbf ft) – –

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

– – –

Loctite ® 648™

Loctite ® 243™

Loctite ® 243™

– – – –

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

Loctite ® 243™

– –

Loctite ® 243™

– – –

Loctite ® 243™ Loctite ® 243™

Only applies when using: Hex key bit (61229025000) – – – – –

Loctite ® 243™

Loctite ® 243™ Loctite ® 243™ 97

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Screw, conrod bearing M10x1 Screw, timing chain tensioner release Cylinder head screw M10x1 M11x1.5

Coolant temperature sensor Rotor screw Spark plug Oil drain plug Nut, inner clutch hub Plug, timing-chain tensioner Screw in alternator cover Nut, primary gear M12x1.5

M12x1.5

M12x1.5

M20x1.5

M22x1.5

M24x1.5

M24x1.5

M33LHx1.5

Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° 10 Nm (7.4 lbf ft) Tightening sequence: Using a crisscross pattern Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° Step 4 90° 12 Nm (8.9 lbf ft) 90 Nm (66.4 lbf ft) 17 Nm (12.5 lbf ft) 20 Nm (14.8 lbf ft) 130 Nm (95.9 lbf ft) 25 Nm (18.4 lbf ft) 8 Nm (5.9 lbf ft) 130 Nm (95.9 lbf ft) – – Lubricated with engine oil – – – –

Loctite ® 243™

– –

Loctite ® 243™ 98

TECHNICAL DATA - CHASSIS

Frame Fork Shock absorber Suspension travel Front Rear Brake system Front Rear Brake discs - diameter Front Rear Brake discs - wear limit Front Brake disc - wear limit Rear Tire air pressure Front Rear Secondary drive Chain Steering head angle Wheelbase Seat height, unloaded Ground clearance, unloaded Weight without fuel approx.

Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible total weight Battery Fuse Fuse Fuse YTZ14S 58011109130 58011109110 58011109105 21.1

Tires Front tire 120/70 R 17 TL

Dunlop Sportmax GP Racer D211 Slick Additional information is available in the Service section under: http://www.ktm.com

Lattice frame made of chromium molybdenum steel tubing, powder-coated

WP Suspension

Up Side Down 4354

WP Suspension

4618 DACC 120 mm (4.72 in) 120 mm (4.72 in) Twin floating disc with radial mount, 4-piston calipers Single non-floating disc with 2 piston brake caliper 320 mm (12.6 in) 220 mm (8.66 in) 4.5 mm (0.177 in) 4.5 mm (0.177 in) 2.0 bar (29 psi) 1.5 bar (22 psi) 17:38 5/8 x 1/4” (520) X ‑ ring 66.7° 1,425 mm (56.1 in) 845 mm (33.27 in) 110 mm (4.33 in) 173 kg (381 lb.) 150 kg (331 lb.) 240 kg (529 lb.) 300 kg (661 lb.) Battery voltage: 12 V Nominal capacity: 11.2 Ah maintenance-free 30 A 10 A 5 A

Rear tire 200/55 R 17 TL

Dunlop Sportmax GP Racer D211 Slick

99

TECHNICAL DATA - CHASSIS

21.2

Capacity - fuel

Total fuel tank capacity, approx.

16.5 l (4.36 US gal)

Super unleaded (ROZ 100) ( p. 119)

100

TECHNICAL DATA - FORK

Fork part number Fork Compression damping Standard Rebound damping Standard Spring preload -

Preload Adjuster

Standard Spring length with preload spacer(s) Spring rate Medium (standard) Air chamber length Fork length

Fork oil ( p. 119)

05.18.7E.10

WP Suspension

Up Side Down 4354 3 clicks 9 clicks 4 turns 405 mm (15.94 in) 9.5 N/mm (54.2 lb/in) 110 +0 − 40 mm (4.33

+0 − 1.57

735 mm (28.94 in) in) SAE 5

101

TECHNICAL DATA - SHOCK ABSORBER

Shock absorber part number Shock absorber Compression damping, high-speed Standard Compression damping, low-speed Standard Rebound damping Standard Spring preload -

Preload Adjuster

Standard Spring rate Medium (standard) Spring length Gas pressure Static sag Riding sag Inbuilt length

Shock absorber oil ( p. 119)

15.18.7E.4402

WP Suspension

4618 DACC 10 clicks 8 clicks 12 clicks 5 turns 80 N/mm (457 lb/in) 150 mm (5.91 in) 10 bar (145 psi) 11… 15 mm (0.43… 0.59 in) 27… 35 mm (1.06… 1.38 in) 291 mm (11.46 in) SAE 2.5

102

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

Remaining frame bolts Screw, brake fluid reservoir of rear brake Screw, brake line holder Screw, chain guard Screw, chain sliding guard Screw, fuel tank cover Screw, fuel tank guard Screw, steering damper fixing bracket Bolt, foot brake lever stub Remaining chassis nuts Remaining chassis screws Screw for wheel speed sensor bracket Screw, foot brake cylinder Screw, foot brake lever Screw, fuel pump Screw, shift lever stub Screw, shift rod Screw, shift shaft deflector on chain securing guide Screw, shift shaft deflector on shift shaft Fork end pinch bolts Nut, forked bracket on foot brake lever Remaining chassis nuts Remaining chassis screws Screw for lifting gear support, rear Screw of rear brake caliper Screw, bottom triple clamp Screw, clamp, eccentric shaft of deflector Screw, front brake disc Screw, front footrest bracket Screw, handlebar stub Screw, rear brake disc Screw, shift lever Screw, steering damper clamp on con sole Screw, steering damper fixing bracket on triple clamp Screw, steering stem Screw, subframe Screw, top triple clamp Remaining chassis nuts Remaining chassis screws Screw, connecting lever, shock absorber deflector Screw, engine bearer Screw, shock absorber Rear sprocket bolt Screw, front brake caliper Nut of bell crank on frame Nut, swingarm pivot M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M5 M5 M5 M5 M5x17 M5 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M10 M10x1.25

M10x1.25

M14x1.5

M19x1.5

5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 3 Nm (2.2 lbf ft) 3 Nm (2.2 lbf ft) 5 Nm (3.7 lbf ft) 10 Nm (7.4 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 3 Nm (2.2 lbf ft) 10 Nm (7.4 lbf ft) 15 Nm (11.1 lbf ft) 6 Nm (4.4 lbf ft) 10 Nm (7.4 lbf ft) 12 Nm (8.9 lbf ft) 7 Nm (5.2 lbf ft) 18 Nm (13.3 lbf ft) 15 Nm (11.1 lbf ft) 30 Nm (22.1 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 18 Nm (13.3 lbf ft) 22 Nm (16.2 lbf ft) 15 Nm (11.1 lbf ft) 18 Nm (13.3 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 20 Nm (14.8 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 20 Nm (14.8 lbf ft) 10 Nm (7.4 lbf ft) 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 17 Nm (12.5 lbf ft) 50 Nm (36.9 lbf ft) 45 Nm (33.2 lbf ft) 45 Nm (33.2 lbf ft) 45 Nm (33.2 lbf ft) 45 Nm (33.2 lbf ft) 50 Nm (36.9 lbf ft) 45 Nm (33.2 lbf ft) 100 Nm (73.8 lbf ft) 130 Nm (95.9 lbf ft)

Loctite ® 243™ Loctite ® 243™

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

– – – –

Loctite ® 243™ Loctite ® 243™

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

– Thread greased –

Loctite ® 243™

– – – – –

Loctite ® 243™ Loctite ® 243™

– –

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

Loctite ® 243™

– –

Loctite ® 243™ Loctite ® 243™

– –

103

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

Bolt, front axle Nut, rear wheel spindle Screw, steering head M25x1.5

M25x1.5

M25x1.5

45 Nm (33.2 lbf ft) 90 Nm (66.4 lbf ft) 18 Nm (13.3 lbf ft) – Thread greased –

104

105

WIRING DIAGRAM

25.1

Page 1 of 6

bl br rd-bu bl 4 3 4 3 30A 2 1 1 2 bl wh-rd wh-rd bl bl gn gn EM/3 EN/3 2 1 1 2 wh-rd wh-rd rd 2 2 10A 1 1 wh-rd rd rd-bu rd 4 1 1 4 3 2 2 3 ye-rd ye-rd wh-or 2 2 1 1 ye-rd rd 1 1

106

101265-01

WIRING DIAGRAM Components:

F1 G10 G20 K10 M10 P10 R10 S23 T20 Fuse Battery Alternator Starter relay with main fuse Starter motor Combination instrument Diode Emergency OFF switch, electric starter button Voltage regulator

107

WIRING DIAGRAM

25.2

Page 2 of 6 108

gn 2 2 10A 1 1 wh-rd br wh-or or 2 2 3 3 1 1 4 4 br gn bl-ye 2 2 10A 1 1 wh-rd wh-or bl-ye 2 2 4 4 1 1 3 3 bu-gr bl-bu br 3 3 1 1 bl-bu or ye-gn 3 3 ye-gn ye-gn 2 1 or 2 1 2 1 or bl-or 1 1 bl-ye br or 3 4 3 4 2 1 1 2 wh-rd gn gn-gr gn-gr 1 1 1 1 gn-gr bu-gr 2 2 or 2 2 bl-or ye-gn bl-ye 9 9 11 11 6 6 wh-rd gn 21 22 21 22 gn-gr 15 15 101266-01

WIRING DIAGRAM Components:

A11 B22 B35 B70 F2 F3 K30 K40 M13 P10 S35 EFI control unit Coolant temperature sensor (cylinder 2) Oil pressure sensor Wheel speed sensor, front Fuse Fuse Power relay Fuel pump relay Fuel pump Combination instrument

MODE

/

LAP

button

109

WIRING DIAGRAM

25.3

Page 3 of 6 110

bl-rd 2 2 5A 1 1 ye-rd bl-rd br 1 1 1 1 or wh-br or wh-pu 1 2 1 1 2 1 1 2 2 1 1 2 bu bl bu bl bl 2 2 bl 2 2 1 1 rd 1 1 rd 3 4 5 6 7 2 1 1 2 3 4 5 6 7 1 1 2 2 3 4 5 3 4 5 bu 1 1 rd 1 1 wh-pu wh-br 29 26 29 26 101267-01

WIRING DIAGRAM Components:

A11 A40 B27 F4 R51 R52 S40 EFI control unit Quick shifter control unit Quick shifter Fuse Ignition coil (cylinder 1) Ignition coil (cylinder 2) Quick shifter switch

111

WIRING DIAGRAM

25.4

Page 4 of 6 112

pu bl-bu wh pu gr gn bu ye rd gr gn-rd wh 3 11 7 15 16 12 8 5 9 4 3 11 7 15 5 9 4 16 12 8 10 6 10 6 bl-gr ye-or bu-or gn-or wh-rd gn bu-pk ye-gn wh-gn br-gr rd-pu bl-rd wh 2 2 3 1 3 1 bl bu gn-rd 1 1 3 2 2 3 bu bl gr rd ye bu 2 1 3 4 1 2 3 4 gn gr pu wh 1 3 2 4 1 2 3 4 bl-bu 2 2 1 1 or pu 2 2 or bu bl 13 14 2 13 14 2 1 1 or or bu bl bl-gr ye-or bu-or gn-or wh-rd gn bu-pk ye-gn wh-gn br-gr rd-pu bl-rd 4 22 12 21 23 7 11 5 6 3 5 6 3 23 7 11 4 22 12 21 2 10 2 10 101268-01

WIRING DIAGRAM Components:

A11 B10 B11 M51 M52 M61 M62 EFI control unit Throttle position sensor circuit A Throttle position sensor circuit B Injector (cylinder 1) Injector (cylinder 2) Motor drive circuit A Motor drive circuit B

113

WIRING DIAGRAM

25.5

Page 5 of 6 114

br br-pu br br bl 1 1 2 2 bl-ye bl 2 1 2 br 3 3 pk 6 4 3 2 br lbu wh-bu bl-bu 3rd 2nd N 3 2 1 3 bl-gn br-pu 6 6 br br 8 9 8 9 bl-ye 9 9 pk 26 26 lbu 17 17 wh-bu bl-bu 20 19 20 19 bl-gn wh-bu wh 19 19 14 16 14 16 2 1 1 2 bl-bu wh-bu br br wh wh-bu bl-gn wh-bu bl-bu br br 20 10 17 20 10 17 5 4 5 4 18 3 18 3 101269-01

WIRING DIAGRAM Components:

A11 B21 B34 P10 R30 R45 X295 EFI control unit Coolant temperature sensor (cylinder 1) Gear position sensor Combination instrument CAN bus terminating resistor Resistance Diagnostics connector

115

WIRING DIAGRAM

25.6

Page 6 of 6 116

bl bu 4 6 4 3 6 5 1 2 5 ye-rd bu bl 1 2 1 2 3 3 gn-gr bu bl 1 2 1 2 3 3 bl-bu bu bl 1 2 1 2 3 3 pu bl bu bl 1 1 2 2 rd 2 1 1 2 ye-bu wh-ye ye-rd gn-gr bl-bu 4 4 23 23 24 24 pu 3 3 rd 22 22 ye-bu wh-ye 13 14 13 14 bl bu 7 7 1 1 or or 1 or 20 20 101270-01

WIRING DIAGRAM Components:

A11 B12 B13 B26 B37 B41 B42 X295 EFI control unit Intake air temperature sensor Ambient air pressure sensor Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Manifold absolute pressure sensor (cylinder 2) Diagnostics connector or pk pu rd wh ye

Cable colors:

bl br bu gn gr lbu Black Brown Blue Green Gray Light blue Orange Pink Violet Red White Yellow

117

SUBSTANCES 118 Brake fluid DOT 4 / DOT 5.1

According to

– DOT

Guideline

– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre sponding properties. KTM recommends

Castrol

and

Motorex ®

products.

Supplier Castrol

RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®

Brake Fluid DOT 5.1

Coolant Guideline

– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam ing. KTM recommends

Motorex ®

products.

Mixture ratio

Antifreeze protection: − 49 °F) − 25… − 45 °C ( − 13… 50 % corrosion inhibitor/antifreeze 50 % distilled water

Coolant (mixed ready to use)

Antifreeze

Supplier Motorex ®

Anti Freeze

− 40 °C ( − 40 °F)

Engine oil (SAE 10W/50) According to

JASO T903 MA (

SAE ( p. 121) p. 121) (SAE 10W/50)

Guideline

– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre sponding properties. KTM recommends

Motorex ®

products.

Fully synthetic engine oil

Supplier Motorex ®

Power Synt 4T Engine oil (SAE 5W/40) According to

JASO T903 MA (

SAE ( p. 121) p. 121) (SAE 5W/40)

Guideline

– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre sponding properties. KTM recommends

Motorex ®

products.

Synthetic engine oil

Supplier Motorex ®

Power Synt 4T

SUBSTANCES 119 Fork oil (SAE 5) According to

SAE ( p. 121) (SAE 5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends

Motorex ®

products.

Supplier Motorex ®

Racing Fork Oil Hydraulic fluid (15) According to

– ISO VG (15)

Guideline

– Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre sponding properties. KTM recommends

Motorex ®

products.

Supplier Motorex ®

Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1) According to

SAE ( p. 121) (SAE 2.5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

Super unleaded (ROZ 100) According to

– DIN EN 228 (ROZ 100)

AUXILIARY SUBSTANCES Air filter cleaner Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Twin Air Dirt Bio Remover Air filter oil Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Air Filter Oil Spray 655 Chain cleaner Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Chain Clean Chain lube for road use Guideline

– KTM recommends

Motorex ® Supplier Motorex ®

Chainlube Road

products.

Long-life grease Guideline

– KTM recommends

Motorex ® Supplier Motorex ®

Bike Grease 2000

products.

Motorcycle cleaner Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Clean & Polish 120

STANDARDS 121 JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements.

– the JASO T903 MA Standard. Ear-

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity. The viscosity describes only one property of oil and says nothing about quality.

INDEX 122

INDEX

A Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Air filter

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

B Battery

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Blank time of the LAP button LAP BLANK TIME

setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Blink code

engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-94

Brake disc, rear

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Brake discs, front

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 66

rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 66

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 67

Brake linings

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 67

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 68

C Care

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91-92

Chain

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91-92

Clutch

fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 64 fluid level, correcting . . . . . . . . . . . . . . . . . . . . . . . . 64

Clutch lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 63

Combination instrument

activation and test . . . . . . . . . . . . . . . . . . . . . . . . . . 12

additional functions menu,

OPTIONS

external temperature display menu,

. . . . . . . . . . . 27, 30

display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

OPTION OUTTEMP

28, 30

fuel reserve display menu,

LAP

button blank time,

TRIP F RESET

. . . . . . . 25, 29-30

FUELDISTANCE

menu . . . . . . . . . . . . . . . . . . . . 16, 29-30

function buttons, handlebar . . . . . . . . . . . . . . . . . . . . 11

indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 info display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

kilometers/miles menu,

SET KM/MILES

. . . . . . . . 26, 29-30

LAP BLANK TIME

menu . . . 24, 29-30

LAP

/

BESTLAP

/

LastLap

menu . . . . . . . . . . . . . . . . 19, 29-30

maximum lap speed menu, maximum speed menu,

LAP

/

TOPSPEED BESTLAP

/

. . . . . . . . 19, 29-30

TopSpeed

. . 20, 29-30

mode menu,

CHANGE MODE

. . . . . . . . . . . . . . . 22, 29-30

next service menu,

DISTANCE TO Next Service

notes/warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

number of laps menu,

SET NUM LAPS

. . . 17, 29-30 . . . . . . . . 24, 29-30

odometer menu, odometer menu,

ODO

/

Trip 1 ODO

/

Trip 2

. . . . . . . . . . . . . . . 15, 29-30 . . . . . . . . . . . . . . . 16, 29-30

remaining laps menu,

LAPSTOGO SETTINGS

menu . . . . . . . . . . . . . . . . . . . . . . . 23, 29-30

SET

UP

menu . . . . . . . . . . . . . . . . . . . . . . . . . 21, 29-30

shift warning lamp menu,

SHIFT RPMS

. . . . . . . . 23, 29-30

temperature display menu,

. . . . . . . . . . . . 18, 29-30

SET °C/°F

. . . . . . . . . 26, 29-30

time menu,

SET CLOCK

. . . . . . . . . . . . . . . . . . 22, 29-30

tire pressure monitor menu,

TPMS

. . . . . . . . . . . . . 27, 30

total distance in

UNITS Race

mode menu,

RACEODO

. . . 20, 29-30 menu . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 29-30

Coolant

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Cooling system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

compensating tank, filling . . . . . . . . . . . . . . . . . . . . . 80

E Electric starter button Emergency OFF switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine

running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Engine number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engine oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Engine sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Environment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Exhaust cover

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

External temperature display

hiding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

F Filler cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Filling up

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Foot brake lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Foot brake lever stub

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

INDEX 123 Footrest position

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fork

compression damping, adjusting . . . . . . . . . . . . . . . . . 43

fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 54

rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 43 spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 43

Fork part number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Frame sliders, front

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Frame sliders, rear

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Fuel overflow reservoir

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Fuel tank

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fuse

individual power consumers, changing . . . . . . . . . . . . . 78

H Hand brake lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 65

Handlebar

handlebar height . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 handlebar height, adjusting . . . . . . . . . . . . . . . . . . . . 51

K Kilometers/miles SET KM/MILES

setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

L Lap times

displaying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

M Main fuse

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Materials

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maximum speed

displaying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

raising the front with lifting gear . . . . . . . . . . . . . . . . . 53 raising the rear with lifting gear . . . . . . . . . . . . . . . . . 53 removing the front from the lifting gear . . . . . . . . . . . . 53 removing the rear from the lifting gear . . . . . . . . . . . . . 53

N Number of laps SET NUM LAPS

setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

O Oil filter

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Owner's manual

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P Play in the throttle cable

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Preparing for use

advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 37

after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

checks and maintenance measures when preparing for use 39

Q Quick shifter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

setting, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 setting, tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Quick shifter switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

R RACE mode

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Rear hub cush drive

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Rear sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Rear wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

ROAD mode

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

S Seat

fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Service schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-42

SET °C/°F temperature unit

setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SET CLOCK

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Shift lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Shift lever stub

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Shift speed RPM1/2

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Shock absorber

compression damping, general . . . . . . . . . . . . . . . . . . 44 compression damping, high-speed, adjusting . . . . . . . . 44 compression damping, low-speed, adjusting . . . . . . . . . 44

rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 45 spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 45

Shock absorber part number

. . . . . . . . . . . . . . . . . . . . . . . . 9

INDEX Side cover, left

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Side cover, right

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Spare parts Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Steering damper

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Steering damper part number Storage

. . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

T Technical data

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99-100

chassis tightening torques . . . . . . . . . . . . . . . . . 103-104

engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-96

engine tightening torques . . . . . . . . . . . . . . . . . . . 97-98

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Throttle cable play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Throttle grip

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Tire air pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Tire condition

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Transport Type label

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

U Use definition

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V Vehicle identification number

. . . . . . . . . . . . . . . . . . . . . . . 9

Vehicle level

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

front, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 rear, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

View of vehicle

front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

W Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wiring diagram

. . . . . . . . . . . . . . . . . . . . . . . . . .

106-117

page 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

page 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

page 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

page 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

page 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

page 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Work rules

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

124

*3211798en*

3211798en

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

09/2011 Photo: Mitterbauer

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