OWNER'S MANUAL 2019 1090 Adventure R Art. no.
DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports vehicle that will continue giving you pleasure for a long time if you maintain it properly. DEAR KTM CUSTOMER We wish you good and safe riding at all times! Please enter the serial numbers of your vehicle below. Vehicle identification number ( Engine number ( Key number ( p. 34) Dealer's stamp p. 36) p.
DEAR KTM CUSTOMER Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard.
TABLE OF CONTENTS TABLE OF CONTENTS 1 1.1 1.2 2 Symbols used .................................. 10 Formats used................................... 11 SAFETY ADVICE.......................................... 12 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 3 3.2 3.3 3.4 3.5 3.6 MEANS OF REPRESENTATION .................... 10 Use definition – intended use............ Misuse............................................ Safety advice...................................
TABLE OF CONTENTS 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.5 6.5.1 6.5.2 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 4 Light switch ................................ Hazard warning flasher switch....... Menu switch................................ Turn signal switch........................ Horn button ................................ Switches on the right side of the handlebar........................................ Emergency OFF switch ................. Electric starter button .
TABLE OF CONTENTS 7.10.15 7.10.16 7.10.17 7.10.18 7.10.19 7.10.20 8 79 80 80 81 82 82 ERGONOMICS ............................................ 84 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 9 "Pressure" ................................... "Fuel Cons" ................................. "Clock/Date" ................................ "Shift Light" ................................ "Heat Grip".................................. "DRL" ......................................... Handlebar position.....................
TABLE OF CONTENTS 12.4 12.5 12.6 12.7 12.8 12.9 Adjusting the spring pretension of the fork......................................... Compression damping of the shock absorber........................................ Adjusting the low-speed compression damping of the shock absorber........................................ Adjusting the high-speed compression damping of the shock absorber........................................ Adjusting the rebound damping of the shock absorber .........................
TABLE OF CONTENTS 13.25 13.26 13.27 13.28 13.29 13.30 13.31 13.32 Removing the fuel tank cover .......... Installing the fuel tank cover ........... Removing the windshield ................ Installing the windshield................. Removing the engine guard............. Installing the engine guard ............. Removing the crash bar .............. Installing the crash bar ............... 168 170 172 172 173 173 174 176 14 BRAKE SYSTEM ....................................... 180 14.1 14.2 14.3 14.4 14.
TABLE OF CONTENTS 16.14 Activating/deactivating the ignition key ............................................... 16.15 Diagnostics connector .................... 16.16 Front ACC1 and ACC2 .................... 16.17 ACC1 and ACC2 rear ...................... 21 STORAGE ................................................. 272 242 248 249 249 22 TROUBLESHOOTING ................................ 274 17 COOLING SYSTEM .................................... 250 23 TECHNICAL DATA.....................................
TABLE OF CONTENTS 28 LIST OF ABBREVIATIONS.......................... 304 29 LIST OF SYMBOLS.................................... 305 29.1 29.2 29.3 Red symbols.................................. 305 Yellow and orange symbols.............. 305 Green and blue symbols.................. 306 INDEX .............................................................
1 MEANS OF REPRESENTATION 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding.
MEANS OF REPRESENTATION 1 Indicates a voltage measurement. Indicates a current measurement. Indicates the end of an activity, including potential rework. 1.2 Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name® Indicates a protected name. Brand™ Indicates a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.
2 SAFETY ADVICE Use definition – intended use 2.1 The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle terrain (unpaved roads). This vehicle is not suitable for use on race tracks. Info This vehicle is only authorized for operation on public roads in its homologated version. 2.2 Misuse The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended.
SAFETY ADVICE 2 Info Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. 2.4 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
2 SAFETY ADVICE 2.
SAFETY ADVICE 2 1 Information on suspension tuning 2 Canada type label 3 Information on emission control 4 Information on chain tension 5 Information on noise emission 6 Information on starting up 7 Information on tires 8 USA type label Information on suspension tuning A00211-10 15
2 SAFETY ADVICE Canada type label A00212-10 Information on emission control A00463-10 16
SAFETY ADVICE 2 Information on chain tension S00938-01 Information on noise emission A00464-10 17
2 SAFETY ADVICE Information on starting up S00940-01 Information on tires M00608-01 18
SAFETY ADVICE 2 USA type label A00215-10 2.6 Reporting safety defects If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives multiple similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
2 SAFETY ADVICE 2.7 Noise emission warranty KTM warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This manufacturer warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985-3553 www.ktmusa.com KTM Canada, Inc.
SAFETY ADVICE 2 ter, ignition coils, ignition wire, capacitors, and spark plugs, if a fault occurs before the first scheduled replacement and includes the hoses, fittings, and pipes that are used directly in these components. If the warranty conditions are met, KTM will repair your motorcycle for you free of charge, including diagnosis, parts, and labor. As the owner of the motorcycle, you are responsible for the required maintenance specified in the Owner's Manual.
2 SAFETY ADVICE www.ktmcanada.com Different rights may apply, according to national or regional legislation. 2.11 Tampering warning Tampering with the noise control system is prohibited.
SAFETY ADVICE 2 2.12 Safe operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. – Do not operate the vehicle if you are physically or mentally impaired. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine.
2 SAFETY ADVICE 2.13 Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.
SAFETY ADVICE 2 2.15 Environment If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others. When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.
3 IMPORTANT NOTES 3.1 Manufacturer warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in the KTM Dealer.net, otherwise any warranty claim will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle is not covered by the manufacturer warranty.
IMPORTANT NOTES 3 The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com 3.4 Service A prerequisite for perfect operation and the prevention of premature wear is that the service, care, and tuning work on the engine and chassis are properly carried out as described in the Owner's Manual. Poor suspension settings can result in damage to the components. Using the motorcycle in extreme operating conditions, e.g.
3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.
IMPORTANT NOTES 3 29
4 VIEW OF VEHICLE 4.
VIEW OF VEHICLE 4 1 2 3 4 5 6 7 8 9 bk Clutch lever ( Seat lock ( p. 38) p. 53) Grab handles ( p. 54) Luggage rack plate ( Passenger foot pegs ( Rider footrests ( p. 54) p. 56) p. 89) Shift lever ( p. 56) Side stand ( p. 58) Engine oil level viewer Fuel cocks ( p.
4 VIEW OF VEHICLE 4.
VIEW OF VEHICLE 4 1 2 3 4 4 5 6 7 8 9 Shock absorber compression adjustment Combination switch ( p. 39) Fork compression adjuster Electric starter button ( p. 44) Emergency OFF switch ( Hand brake lever ( p. 44) p. 38) Storage compartment Cooling system compensating tank Foot brake lever ( p.
5 SERIAL NUMBERS 5.1 Vehicle identification number 1 The vehicle identification number is stamped on the bottom right of the frame behind the steering head. The vehicle identification number is also shown on the type label. 402294-10 5.2 Type label 1 Type label USA is affixed to the frame behind the steering head at the top right.
SERIAL NUMBERS 5 2 is affixed to the frame behind the steering Type label Canada head at the top left. 402293-11 5.3 Key number The key number Code number the KEYCODECARD. 1 can be found on Info 402771-10 You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.
5 SERIAL NUMBERS 5.4 Engine number The engine number 1 is stamped on the right side of the engine. 402296-10 5.5 Fork part number The fork part number stub.
SERIAL NUMBERS 5 5.6 Shock absorber article number The shock absorber article number the shock absorber.
6 CONTROLS 6.1 Clutch lever 1 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M00546-10 6.2 Hand brake lever 1 The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.
CONTROLS 6 6.3 Throttle grip The throttle grip 1 is fitted on the right side of the handlebar. S01749-11 6.4 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar.
6 CONTROLS Overview of the left combination switch Light switch ( p. 40) 1 2 3 4 5 Hazard warning flasher switch ( Menu switch ( Turn signal switch ( Horn button ( p. 41) p. 42) p. 42) p. 43) M00547-10 6.4.2 Light switch The light switch left. 1 is fitted on the combination switch on the Possible states Low beam on – Light switch in position . In this position, the low beam and tail light are switched on. A High beam on – Push the light switch to position .
CONTROLS 6 6.4.3 Hazard warning flasher switch 1 The hazard warning flasher switch is fitted on the combination switch on the left. The hazard warning flasher is used to indicate emergency situations. Info 602606-10 The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 60 seconds after the ignition is switched off. Only keep the hazard warning flasher activated as long as necessary as it depletes the 12-V battery.
6 CONTROLS 6.4.4 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the matrix display on the combination instrument. Button is the UP button. Button is the DOWN button. Button is the SET button. Button is the BACK button. 1 2 3 4 S00224-11 6.4.5 Turn signal switch Turn signal switch left. 1 is fitted on the combination switch on the Possible states Turn signal off – Push the turn signal switch toward the switch housing.
CONTROLS 6 Info An automatic turn signal switch-off function (ATIR) is available as an optional software feature. The ATIR function uses a time and distance counter. If the turn signal has been on for at least 10 seconds and 150 meters of riding distance, the turn signal is switched off. If the vehicle is stationary, both counters are stopped. If the turn signal switch is reactivated, both counters are reset. 6.4.6 Horn button The horn button left. Possible states • Horn button • Horn button tion.
6 CONTROLS 6.5 Switches on the right side of the handlebar 6.5.1 Emergency OFF switch The emergency OFF switch handlebar. 1 is fitted on the right side of the Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started. A message appears on the matrix display. S01750-10 6.5.2 Emergency OFF switch on – This position is required for operation; the ignition circuit is closed.
CONTROLS 6 6.6 Ignition and steering lock The ignition and steering lock triple clamp. 1 is located in front of the upper Info The ignition may only be switched on using a black ignition key. With the orange programming key, you can activate or deactivate the black ignition key. S01751-10 Possible states Ignition off OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a nonrunning engine will not start. The black ignition key can be removed.
6 CONTROLS 6.7 Immobilizer The electronic immobilizer secures the vehicle against unauthorized use. The immobilizer is activated automatically and the engine electronics are locked when the ignition key is withdrawn. The immobilizer indicator lamp can indicate errors by flashing. If the optional alarm system is installed, immobilizer indicator lamp flashes when the alarm system is switched on. 1 1 Info 401815-10 The ignition keys contain electronic components.
CONTROLS 6 6.8 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar all the way to the left. – Insert the ignition key into the ignition and steering lock, press in, and turn to the left. Remove the ignition key. Steering is no longer possible.
6 CONTROLS 6.9 Unlocking the steering – Insert the ignition key into the ignition and steering lock, press in, and turn to the right. Remove the ignition key. The handlebar can now be moved again. 400731-01 6.10 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. 48 – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.
CONTROLS 6 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them.
6 CONTROLS Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced. – – S01753-10 6.11 – 2 clockwise. Fold up fuel tank filler cap 3. – Fold down fuel tank filler cap – Turn ignition key Turn ignition key Closing the fuel tank filler cap S01754-10 50 Push down on the fuel tank filler cap to take pressure off the ignition key. 1. 2 clockwise.
CONTROLS 6 – Push down the fuel tank filler cap and turn the ignition key counterclockwise until the fuel tank filler cap lock closes. 2 Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. S01755-10 – – Check that the fuel tank filler cap is locked correctly after closing. – Change your clothing if fuel spills on them. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. Remove ignition key 2 and close cover 3.
6 CONTROLS 6.12 Fuel cocks A fuel cock 1 is located on each side of the fuel tank. Info The fuel cocks must always be open during operation. The fuel cocks are only closed to remove the fuel tank. D03209-10 6.13 Possible states • Fuel cocks are closed – Level equalization cannot take place and the fuel supply to the throttle valve body is shut off. • Fuel cocks are open – Level equalization can take place and the fuel supply to the throttle valve body is open.
CONTROLS 6 6.14 Closing storage compartment – Press cover 1 downward. The lock engages audibly. S01757-11 6.15 Seat lock 1 The seat lock is located on the left side of the vehicle. It can be unlocked using the ignition key.
6 CONTROLS 6.16 Grab handles The passenger can hold onto the grab handles 1 during the trip. S01765-10 6.17 Luggage rack plate 1 The luggage rack plate is located behind the seat. The base plate of a luggage system (optional) can be attached to the luggage rack plate. The luggage rack plate may not be loaded with more than the specified weight. Maximum permissible load on luggage rack plate S01766-10 54 5 kg (11 lb.
CONTROLS 6 Info Note the information provided by the luggage manufacturer. 6.18 Case holders 1 The case holders are located on each side of the seat. A case system (optional) can be attached on the case holders. Use case systems approved and/or recommended by KTM. Observe the specifications in the enclosed KTM PowerParts fitting instructions. Info E01057-10 The use of other case systems is not recommended. Do not exceed the maximum load of the case holders if using other case systems.
6 CONTROLS 6.19 Passenger foot pegs The passenger foot pegs can be folded up and down. Possible states • Passenger foot pegs folded up – For operation without a passenger. • Passenger foot pegs folded down – For operation with a passenger. S01767-10 6.20 Shift lever The shift lever 402299-10 56 1 is fitted on the left side of the engine.
CONTROLS 6 The gear positions can be seen in the figure. The idle position is between first and second gears. 402299-11 6.21 Foot brake lever 1 Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever.
6 CONTROLS 6.22 Side stand 1 The side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system. See the instructions in the section on “Stopping, parking”. 402029-10 58 Possible states • Side stand folded out – The vehicle can be supported on the side stand. The safety starting system is active.
COMBINATION INSTRUMENT 7 7.1 Overview 1 2 3 4 5 Matrix display ( p. 61) Tachometer Shift warning light ( p. 67) Segment display Indicator lamps ( p. 63) 402341-10 7.2 Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segment display, the indicator lamps, and the tachometer are briefly activated for a function check. The welcome text and information on the next service ( p. 68) appear on the matrix display.
7 COMBINATION INSTRUMENT Info If the 12-V battery was disconnected, the time and date must be set. The brightness of the displays is controlled by an ambient light sensor in the combination instrument. The malfunction indicator lamp always lights up as long as the engine is not running. If the engine is running and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop.
COMBINATION INSTRUMENT 7 7.3 Matrix display The matrix display is controlled using the menu switch ( p. 42). After the ignition is switched on, the display shows when the next service ( p. 68) is due. If among the indicator lamps ( p. 63) the general warning light lights up, the corresponding message appears in the matrix display. The SET button is used to confirm receipt of the information and the message is cleared. Messages appear 10 s S01595-01 7.
7 COMBINATION INSTRUMENT bk 7.5 Ice warning Fuel level display The fuel level display shows the filling level of the fuel tank. Info 402710-01 62 The fuel level is displayed with a slight delay to prevent the indicator from constantly moving while riding. The fuel level display is not updated while the side stand is folded out or the emergency off switch is switched off. Once the side stand is folded up and emergency OFF switch is switched on, the fuel level display is next updated after 2 minutes.
COMBINATION INSTRUMENT 7 7.6 Indicator lamps The indicator lamps offer additional information about the operating state of the motorcycle. When the ignition is switched on, all indicator lamps light up briefly. Info 402343-01 The malfunction indicator lamp always lights up as long as the engine is not running. If the engine is running and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop.
7 COMBINATION INSTRUMENT The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine. The general warning lamp lights up yellow – A note/warning note on operating safety has been detected. This is also shown on the matrix display.
COMBINATION INSTRUMENT 7 TC indicator lamp lights up/flashes yellow – Traction control is not enabled or is currently intervening. The TC indicator lamp also lights up if an error is detected. 7.7 Message on the matrix display Possible states Engine malfunction – The engine control unit has detected an error. Visit an authorized KTM workshop. General message – General message on operating safety. Visit an authorized KTM workshop. ABS warning – ABS is not available. Visit an authorized KTM workshop.
7 COMBINATION INSTRUMENT Coolant temperature – The coolant temperature is too high. Switch off the engine. Contact an authorized KTM workshop. Fuel reserve – The fuel supply is dwindling. Refuel at the next opportunity. Ice warning – The roads may be icy. Adjust your speed to the road conditions. Battery voltage – The battery voltage is too low. Recharge the 12-V battery with a suitable battery charger. Service – A service is due. Contact an authorized KTM workshop.
COMBINATION INSTRUMENT 7 7.8 Shift warning light The shift warning light flashes or lights up when the transmission should be shifted. In the "Shift Light" menu, the engine speed for the shift warning light can be set. The shift warning light flashes over "RPM1" and lights up continuously over "RPM2". Info In sixth-gear, the shift warning light is deactivated when the engine is warm after the first service. The shift warning light can be turned on and off in the "Settings" menu.
7 COMBINATION INSTRUMENT 7.9 service display After the ignition is switched on, the service display appears briefly. The service intervals depend on the distance traveled or the elapsed time. The event that occurs first is given priority. The exact service intervals can be found in the service schedule. S01595-01 7.10 Matrix display menu 7.10.1 "Favorites" – Press the UP or DOWN button until the "Favorites" menu appears on the matrix display. Pressing the SET button opens the menu.
COMBINATION INSTRUMENT 7 In the "Set Favorites" menu, the "Favorites" menu can be configured. 7.10.2 "Trip 1" – L02906-01 Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display. "Trip 1" shows the distance since the last reset, such as between two refueling stops. "Trip 1" runs continuously and counts the distance up to 9999. "Ø Speed 1" indicates the average speed based on "Trip 1" and "Trip Time 1".
7 COMBINATION INSTRUMENT 7.10.3 "Trip 2" – L02907-01 Press the UP or DOWN button until the "Trip 2" menu appears on the matrix display. "Trip 2" shows the distance since the last reset, such as between two refueling stops. "Trip 2" runs continuously and counts the distance up to 9999. "Ø Speed 2" indicates the average speed based on "Trip 2" and "Trip Time 2". "Ø Cons 2" indicates the average fuel consumption based on "Trip 2" and "Trip Time 2".
COMBINATION INSTRUMENT 7 7.10.4 "General Info" – Press the UP or DOWN button until the "General Info" menu appears on the matrix display. "Air Temp" displays the ambient air temperature. "Date" displays the date. "ODO" displays the total distance covered. "Battery" displays the battery voltage. "Oil Temp" - inoperative F00705-01 7.10.5 "Set Favorites" Condition • The vehicle is stationary. 401991-01 – Press the UP or DOWN button until the "Set Favorites" menu appears on the matrix display.
7 COMBINATION INSTRUMENT 7.10.6 "Settings" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. Settings for units or various values are made in the "Settings" menu. Several functions can be enabled or disabled. 402431-10 7.10.7 "Warning" Condition • Message or warning – Press the UP or DOWN button until the "Warning" menu appears on the matrix display.
COMBINATION INSTRUMENT 7 7.10.8 "Heating" (optional) – Press UP or DOWN button until the "Heating" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the SET button to select a heating level or to switch off the heated grips. 402434-02 7.10.9 "MTC/ABS" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "MTC/ABS" menu appears on the matrix display. In the "MTC/ABS" menu, the traction control "TC" and the "ABS" can be switched off.
7 COMBINATION INSTRUMENT Info After the ignition is switched on, traction control and ABS are enabled again. When the "Offroad" ABS mode is enabled, ABS only controls the front wheel. The rear wheel is not controlled by ABS and may lock during braking maneuvers. 7.10.10 "Drive Mod" 402432-01 – Press the UP or DOWN button until the "Drive Mod" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the UP or DOWN button to navigate through the menu.
COMBINATION INSTRUMENT 7 OFFROAD – reduced homologated performance for better ridability; the traction control allows high slip on the rear wheel 75
7 COMBINATION INSTRUMENT 7.10.
COMBINATION INSTRUMENT 7 "KTM" start screen Menu buttons "Favorites" "Trip 1" "Trip 2" "General info" "Set Favorites" "Settings" "Warning" (only active if there are messages) "Heating" (optional) "MTC/ABS" "Drive Mod" 77
7 COMBINATION INSTRUMENT 7.10.12 "Language" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the SET button again to select the language. The menu languages are US English, UK English, German, Italian, French, and Spanish. 402431-10 7.10.13 "Distance" Condition • The vehicle is stationary.
COMBINATION INSTRUMENT 7 7.10.14 "Temp" Condition • The vehicle is stationary. 402431-12 – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Temp" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure. Select "°C" or "°F" for the temperature indicator. 7.10.15 "Pressure" Condition • The vehicle is stationary.
7 COMBINATION INSTRUMENT 7.10.16 "Fuel Cons" Condition • The vehicle is stationary. 402431-14 – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Fuel Cons" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure. Select one of the available consumption displays. 7.10.17 "Clock/Date" Condition • The vehicle is stationary.
COMBINATION INSTRUMENT 7 7.10.18 "Shift Light" Condition • The vehicle is stationary. L01433-10 – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Shift Light" is highlighted in black on the matrix display. Pressing the SET button again opens the menu. – Press the UP or DOWN button to select the function. Use the SET button to set the engine speed for the shift warning light.
7 COMBINATION INSTRUMENT 7.10.19 "Heat Grip" Condition • The vehicle is stationary. L01439-15 – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Heat Grip" is highlighted in black on the matrix display. Pressing the SET button again switches the heated grips menu on or off. Switch the heated grips menu on and off. 7.10.20 "DRL" Condition • The vehicle is stationary.
COMBINATION INSTRUMENT 7 Warning Danger of accidents When visibility is poor, the daytime running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain. – – Ensure that the appropriate type of lighting is always selected.
8 ERGONOMICS 8.1 Handlebar position The holes on the handlebar support are placed at a distance of from the center. Hole distance A A 3.5 mm (0.138 in) The handlebar can be mounted in two different positions. In this way, the handlebar can be mounted in the position that is most comfortable for the rider. 401666-11 8.2 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued.
ERGONOMICS 8 – 1 Remove screws . Remove the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not bend the cables and lines. 308080-01 – Remove screws – Place the handlebar supports in the required position. Mount and tighten screws . 2. Take off the handlebar supports. 2 Guideline Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™ Info Position the left and right handlebar supports evenly.
8 ERGONOMICS Guideline Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) Info Make sure the gap widths are even. 8.3 Adjusting the wind shield – Pull the clamping lever 1 in the direction of the arrow. The windshield is unlocked.
ERGONOMICS 8 – Move the wind shield in the required position. – Push the clamping lever S01769-10 1 in the direction of the arrow. The windshield is locked.
8 ERGONOMICS 8.4 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw . 1 Info M00551-10 88 When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar. When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. The range of adjustment is limited. Only turn the adjusting screw by hand, and do not use force.
ERGONOMICS 8 8.5 Adjusting the basic position of the hand brake lever – Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel . 1 Info Push the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding. S01770-10 8.6 Rider footrests The rider footrests can be mounted in one of two positions.
8 ERGONOMICS 8.7 Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides. – Remove screw 1. The foot brake lever swings up to the stop. M00622-10 – – 2 with washer 3. Carefully remove the pin 4 of the rider footrest. Remove pin Info The spring is under high tension and can pop out when the pin is removed. – M00640-10 90 Take off the rider footrest 5 with the spring.
ERGONOMICS 8 – Remove screws – Adjust the footrest bracket to the desired position. 6.
8 ERGONOMICS – Mount and tighten screws 6. Guideline Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite®243™ M00641-10 – Mount the rider footrest with spring 5 and pin 4. Footrest spring plier (58429083000) – M00642-10 92 Mount the washer 3 and pin 2.
ERGONOMICS 8 – Position the foot brake lever. – Mount and tighten screw 1. Guideline Screw, ball joint of push rod on foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™ M00622-10 8.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
8 ERGONOMICS – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. A Distance between shift lever and upper edge of boot A 0 » 10 … 20 mm (0.39 … 0.79 in) If the distance does not meet specifications: – Set the basic position of the shift lever. ( 400692-10 8.9 Adjusting the basic position of the shift lever – Remove screw lever . 2 402299-12 94 1 with the washers and take off shift p.
ERGONOMICS 8 – Clean gear teeth – Mount the shift lever on the shift shaft in the required position and engage the gearing. A of the shift lever and shift shaft. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure. A 0 402300-10 – Mount and tighten screw 1 with the washers. Guideline Screw, shift lever M6 15 Nm (11.
8 ERGONOMICS 8.10 Adjusting the basic position of the foot brake lever – – – – 1. Loosen nut 2. Remove screw 3. Detach spring To adjust the basic position of the foot brake lever to individual requirements, turn ball joint accordingly. 4 Info The range of adjustment is limited. The screw must be screwed into the ball joint by at least 5 turns. S00283-10 – Hold ball joint 4 and tighten nut 2. Guideline Remaining nuts, chassis – M6 Mount and tighten screw 10 Nm (7.4 lbf ft) 3.
PREPARING FOR USE 9 9.1 Advice on preparing for first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. – Do not operate the vehicle if you are physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk.
9 PREPARING FOR USE Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened. – Run in new tires with moderate riding at alternating angles. Running-in phase 200 km (124 mi) Warning Danger of accidents The brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously. – Take your foot off the foot brake lever when you are not braking.
PREPARING FOR USE 9 – Run the engine in. ( 9.2 – p. 99) Running in the engine During the running-in phase, do not exceed the specified engine speed. Guideline Maximum engine speed – During the first: 1,000 km (620 mi) 6,500 rpm After the first: 1,000 km (620 mi) 10,050 rpm Avoid fully opening the throttle! Info If the maximum engine speed is exceeded before the first service, the shift warning light flashes. 9.
9 PREPARING FOR USE Warning Danger of accidents Improper mounting of cases or the tank rucksack impairs the handling characteristic. – Mount and secure cases and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. – Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage. Maximum speed with luggage 150 km/h (93.
PREPARING FOR USE 9 Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic. – Check that your luggage is fixed properly at regular intervals. Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system.
10 RIDING INSTRUCTIONS 10.1 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. H02217-01 102 – Check the engine oil level. ( – Check the front brake fluid level. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( – Check the rear brake linings.
RIDING INSTRUCTIONS 10 – 10.2 Check the fuel level. Starting the vehicle Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is discharged or missing.
10 RIDING INSTRUCTIONS – Press the emergency OFF switch to the position ON – Switch on the ignition by turning the black ignition key to the position ON . . After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time. The ABS indicator lamp lights up and goes back out after starting off.
RIDING INSTRUCTIONS 10 Info Do not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start. Press the electric starter button for 5 seconds at most. Wait for a least 5 seconds before trying again. This motorcycle is equipped with a safety starting system.
10 RIDING INSTRUCTIONS 10.4 Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – Adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. – Do not change into a low gear at high engine speed. Warning Danger of accidents An incorrect ignition key position causes malfunctions.
RIDING INSTRUCTIONS 10 Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. – Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot pegs and holds on to the rider or the grab handles. – Note the regulations governing the minimum age of passengers in your country. Warning Danger of accidents A risky riding style constitutes a major risk.
10 RIDING INSTRUCTIONS Warning Danger of accidents Total weight and axle loads influence the handling characteristic. The total weight consists of: motorcycle ready for operation and with a full tank, driver and passenger with protective clothing and helmet, and luggage. – Do not exceed the maximum permissible overall weight or the axle loads. Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic.
RIDING INSTRUCTIONS 10 Note Engine failure Overheating damages the engine. – If the coolant temperature warning is displayed, stop immediately and take care not to endanger yourself or other traffic participants in the process. – Allow the engine and cooling system to cool down. – Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state.
10 RIDING INSTRUCTIONS reduce the speed, but fuel consumption will be considerably lower. 110 – Accelerate only up to a speed suitable for the road surface and weather conditions. Particularly in bends, do not shift, and accelerate very carefully. – Brake if necessary and close the throttle at the same time in order to shift down. – Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and open the throttle or shift again. – If the engine stalls (e.g.
RIDING INSTRUCTIONS 10 Info You can deduce a two-digit number from the flash rhythm – the so-called blink code. The blink code tells you which component is affected by a malfunction. – If the general warning lamp lights up during a trip, the matrix display shows a message for 10 seconds. Info Very important messages are stored in the "Warning" menu. – 10.5 If the ice warning appears on the combination instrument, there may be black ice on the road surface. Adjust your speed to the road conditions.
10 RIDING INSTRUCTIONS Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously. – Take your foot off the foot brake lever when you are not braking.
RIDING INSTRUCTIONS 10 Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. The ABS effectiveness is only ensured if it is switched on. – Leave the ABS switched on in order to benefit from the protective effect. Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations.
10 RIDING INSTRUCTIONS Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. – If possible finish braking before going into a bend. – Always finish braking before you go into a bend. Shift down to a lower gear appropriate to your speed. – Use the braking effect of the engine on long downhill stretches. To do so, shift back one or two gears, but do not overrev the engine.
RIDING INSTRUCTIONS 10 Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle.
10 RIDING INSTRUCTIONS – Lock the steering by turning the handlebar to the left, pressing the black ignition key down in the position OFF and turning it to the position LOCK . To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the black ignition key. 10.7 Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface.
RIDING INSTRUCTIONS 10 – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away. 401475-01 10.8 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
10 RIDING INSTRUCTIONS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them.
RIDING INSTRUCTIONS 10 – Switch off the engine. – Open the fuel tank filler cap. ( – Fill the fuel tank with fuel up to the lower edge neck. Total fuel tank capacity, approx. – p. 48) 23 l (6.1 US gal) Close the fuel tank filler cap. ( A of the filler Super unleaded (ROZ 95/RON 95/PON 91) ( p. 299) p.
11 SERVICE SCHEDULE 11.1 Additional information Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
SERVICE SCHEDULE 11 Every two years Every year every 30,000 km (18,600 mi) every 15,000 km (9,300 mi) after 1,000 km (620 mi) ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. Check the front brake fluid level. ( Check the rear brake fluid level. ( p. 184) p. 189) Check/correct the fluid level of the hydraulic clutch. ( Check steering head bearing play. ( Check the tire condition. ( Check tire pressure. ( ( p. 208) p.
11 SERVICE SCHEDULE Every two years Every year every 30,000 km (18,600 mi) every 15,000 km (9,300 mi) after 1,000 km (620 mi) ● Check the valve clearance (air filter and spark plugs removed). ● Change the SAS diaphragm valves. ● ● ● ● ● ● ● ● Change the air filter, clean the air filter box. ● ● Check the fuel pressure. ● ● ● ● Check the cables for damage and routing without sharp bends. (fuel tank removed) Check the coolant level in the compensating tank. ( p.
SERVICE SCHEDULE 11 11.3 Recommended work Every four years Every year every 30,000 km (18,600 mi) every 15,000 km (9,300 mi) after 1,000 km (620 mi) Check the frame. ● Check the link fork. ● Check/clean the oil nozzle for clutch lubrication. ○ Check the fork bearing for play. ● ● ● ● ● ● Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth operation. ○ ● ● ● ● Empty the drainage hoses. ○ ● ● ● ● ● ● ● ● ● Check the wheel bearing for play.
12 SUSPENSION SETTING 12.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to the riding style and the payload. Info The recommendations for the suspension setting are shown in table . The table is found on the left inside cover of the fuel tank. 1 S01772-10 12.2 These adjustments are guidelines and should always be the basis for a suspension setting.
SUSPENSION SETTING 12 – Turn white adjusting screw 1 clockwise as far as it will go. Info 1 Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in left fork leg COMP (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw). S01773-10 – Turn counterclockwise by the number of clicks corresponding to the fork type.
12 SUSPENSION SETTING 12.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn red adjusting screw 1 clockwise as far as it will go. Info 1 Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in right fork leg REB (red adjusting screw). The compression damping is located in left fork leg COMP (white adjusting screw).
SUSPENSION SETTING 12 Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 12.4 Adjusting the spring pretension of the fork – Turn adjusting screws 1 counterclockwise all the way. Info Make the same adjustment on both fork legs. – Turn clockwise by the number of turns corresponding to the fork type.
12 SUSPENSION SETTING Info Turn clockwise to increase the spring pretension; turn counterclockwise to reduce the spring pretension. Adjusting the spring pretension has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring pretension. 12.5 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
SUSPENSION SETTING 12 12.6 Adjusting the low-speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in the slow to normal compression of the shock absorber.
12 SUSPENSION SETTING Guideline Low-speed compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 12.7 Adjusting the high-speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen.
SUSPENSION SETTING 12 – Turn adjusting screw wrench. 1 all the way clockwise with a socket Info Do not loosen fitting – S01779-10 2! Turn counterclockwise by the number of turns corresponding to the shock absorber type. Guideline High-speed compression damping Comfort 1.5 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12 SUSPENSION SETTING 12.8 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
SUSPENSION SETTING 12 12.9 Adjusting the spring pretension of the shock absorber – Turn handwheel – Turn it clockwise by the number of turns corresponding to the shock absorber type and use. 1 counterclockwise as far as it will go. Guideline Spring preload S01781-10 Comfort 2 turns Standard 2 turns Sport 2 turns Full payload 18 turns Info Turn clockwise to increase the spring pretension; turn counterclockwise to reduce the spring pretension.
13 SERVICE WORK ON THE CHASSIS 13.1 Raising the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Mount the retaining adapter on the link fork. – Insert the adapter in the rear lifting gear. Retaining adapter (61029955144) Rear wheel work stand (69329955000) – Stand the motorcycle upright, align the lifting gear to the link fork with the adapters, and raise the motorcycle. 402346-01 13.
SERVICE WORK ON THE CHASSIS 13 – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the motorcycle on the side stand . – Remove the retaining adapter from the link fork. 1 402029-10 13.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Preparatory work – Raise the motorcycle with the rear lifting gear. ( – Remove the bottom triple clamp cover.
13 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. – Attach the front lifting gear with the adapter on the steering stem. Mounting pin (69329965040) Front wheel work stand, large (69329965000) – 402345-01 Align the front lifting gear with the fork legs. Info Always raise the motorcycle at the rear first. – 13.4 Lift the motorcycle at the front.
SERVICE WORK ON THE CHASSIS 13 Main work – Secure the motorcycle against falling over. – Remove the front lifting gear. 402777-01 Finishing work – Install the bottom triple clamp cover. ( 13.5 p. 155) Raising the motorcycle with the work stand (inserted) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface.
13 SERVICE WORK ON THE CHASSIS – Fold up the rider footrests and secure them. – The plastic bushing of work stand opening of the fork pivot. 1 should engage in the Work stand (62529055200) Info Set the work stand to an appropriate height and width. D03115-10 138 – Raise the motorcycle. – Check that the work stand is properly seated.
SERVICE WORK ON THE CHASSIS 13 13.6 Removing the motorcycle from the work stand (inserted) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface.
13 SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove special tool 1. Work stand (62529055200) Info To avoid damaging components, lower the motorcycle slowly from the work stand. The assistance of a second person can be useful. D03116-10 140 – Lean the motorcycle on the side stand. – Remove the fixing means on the rider footrests.
SERVICE WORK ON THE CHASSIS 13 13.7 Removing the seat – Insert the ignition key in the seat lock wise by 45 °. – Raise the rear of the seat, pull the seat back, and lift it off. – Remove the ignition key. – Hook holding lug of the seat onto the fuel tank, lower the rear and push it forward. – Insert the locking pin into the lock housing and push down the rear of the seat until the locking pin engages with an audible click. – Check that the seat is correctly mounted.
13 SERVICE WORK ON THE CHASSIS 13.9 Checking for chain dirt – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 142) 400678-01 13.10 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. 142 – Always keep the brake discs free of oil and grease.
SERVICE WORK ON THE CHASSIS 13 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 134) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner.
13 SERVICE WORK ON THE CHASSIS 13.11 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
SERVICE WORK ON THE CHASSIS 13 Chain tension » 40 … 45 mm (1.57 … 1.77 in) If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 145) Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 134) 13.12 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.
13 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – – 1. Loosen nuts 2. Adjust the chain tension by turning adjusting screws and right. 3 left Guideline Chain tension 40 … 45 mm (1.57 … 1.77 in) 3 Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. 4 A Info The top chain section must be taut.
SERVICE WORK ON THE CHASSIS 13 Guideline Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased Info Chain adjusters 4 can be turned by 180°. Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 134) 13.13 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 134) Main work – Check the rear sprocket and engine sprocket for wear.
13 SERVICE WORK ON THE CHASSIS – Shift the transmission into neutral – Pull on the lower chain section with the specified weight . A. Guideline Weight, chain wear measurement – Measure distance section. 15 kg (33 lb.) B of 18 chain rollers in the upper chain Info Chain wear is not always even, so you should repeat this measurement at different chain positions. B Maximum distance from 18 chain rollers at the longest chain section 0 » If distance – 402479-10 272 mm (10.
SERVICE WORK ON THE CHASSIS 13 – Check the chain sliding guard for wear at the recess. Info 1 are When the chain sliding guard is new, the rivets half visible at the bottom edge of the recess. C » S01784-10 When the rivets of the chain are no longer visible at the bottom edge of the recess of the chain sliding guard: – – Change the chain sliding guard. Check that the chain sliding guard is firmly seated. » If the chain sliding guard is loose: – Tighten the screws on the chain sliding guard.
13 SERVICE WORK ON THE CHASSIS Guideline Screw, chain guide M6 5 Nm (3.7 lbf ft) Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 134) 13.14 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. 150 – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
SERVICE WORK ON THE CHASSIS 13 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
13 SERVICE WORK ON THE CHASSIS – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water. 13.15 Checking steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.
SERVICE WORK ON THE CHASSIS 13 Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. – Move the handlebar to the straight-ahead position. Move the fork legs back and forth in the direction of travel. Play should not be detectable on the steering head bearing. » 400738-11 If there is detectable play: – – Adjust steering head bearing play. Move the handlebar back and forth over the entire steering range.
13 SERVICE WORK ON THE CHASSIS 13.16 Removing the bottom triple clamp cover – Remove screws – Lower triple clamp cover – Disconnect plugs 1. 2 slightly. M00557-10 M00558-10 154 – 3 of the horn. Detach temperature sensor 4. – Remove the triple clamp cover.
SERVICE WORK ON THE CHASSIS 13 13.17 Installing the bottom triple clamp cover – – 1 of the horn. Attach temperature sensor 2. – Position the triple clamp cover – Mount and tighten screws Plug in connectors M00558-11 3. 4. Guideline Remaining screws, chassis M6 10 Nm (7.
13 SERVICE WORK ON THE CHASSIS 13.18 Removing the front side cover – Remove screw – Remove screws 1. S01786-10 S01787-10 156 – 2. Remove side cover 3. – Repeat these steps on the opposite side.
SERVICE WORK ON THE CHASSIS 13 13.19 Installing the front side cover – Position the side cover in area – Attach side cover to bracket position on the fuel tank. A under the fuel tank cover. S01788-10 Holding lug 1 using holding lug 2 and 3 engages in hole 4.
13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 5. Guideline Screw, cover part M5 3.5 Nm (2.58 lbf ft) S01786-11 – Mount and tighten screws 6. Guideline Screw, cover part – M5 3.5 Nm (2.58 lbf ft) Repeat these steps on the opposite side. S01790-10 13.20 Removing the mask spoiler Preparatory work – Remove the seat. ( 158 p. 141) – Remove the front side cover. ( p. 156) – Remove the fuel tank cover. ( p.
SERVICE WORK ON THE CHASSIS 13 Main work – Remove screw 1. – 2.
13 SERVICE WORK ON THE CHASSIS – Loosen holding lug – Remove the mask spoiler laterally from the supports. 3 from the inside cover.
SERVICE WORK ON THE CHASSIS 13 – Pull the mask spoiler upward from bracket – Disconnect plug-in connector – Remove the mask spoiler with the turn signal. – Repeat the operation on the opposite side. 4. S01795-10 5.
13 SERVICE WORK ON THE CHASSIS 13.21 Installing the mask spoiler Main work – Connect plug-in connector 1. S01796-11 – Position the mask spoiler in bracket 2. Info Ensure that the turn signal cable is placed correctly.
SERVICE WORK ON THE CHASSIS 13 – Press the mask spoiler laterally into the supports. – Position holding lug S01794-11 3 in the drill hole.
13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 4. Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) S01792-11 – Mount and tighten screw 5. Guideline Screw, mask spoiler – M5x17 Repeat the operation on the opposite side. S01791-11 164 3.5 Nm (2.58 lbf ft) Finishing work – Install the fuel tank cover. ( p. 170) – Install the front side cover. ( p. 157) – Mount the seat. ( p.
SERVICE WORK ON THE CHASSIS 13 13.22 Removing front fender – – 1 and detach the brake lines and cable. Remove screws 2. – Take the fender off to the front. Open holder Info Pay attention to the brake lines and the cable. S01797-10 13.23 Installing front fender – Position the fender. Info Pay attention to the routing of the brake lines and the cable. – Mount and tighten screws 1. Guideline S01797-11 Screw, fender M5x12 3.5 Nm (2.
13 SERVICE WORK ON THE CHASSIS – 13.24 Insert the brake lines and cable in brackets holder. 2 and close the Cleaning the dust boots of the fork legs Preparatory work – Remove front fender. ( p. 165) – Raise the motorcycle with the rear lifting gear. ( – Remove the bottom triple clamp cover. ( – Lift the motorcycle with the front lifting gear. ( Main work – Push dust boots p. 134) p. 154) p. 135) 1 of both fork legs downward.
SERVICE WORK ON THE CHASSIS 13 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Clean and oil the dust boots and inner fork tubes of both fork legs. Universal oil spray ( p. 301) – Press the dust boots back into the installation position. – Remove excess oil. Finishing work – Take the motorcycle off the front lifting gear. ( p.
13 SERVICE WORK ON THE CHASSIS 13.25 Removing the fuel tank cover Preparatory work – Remove the seat. ( – Main work – Remove screw – Remove screw – Remove screw – Remove screw 1. 2. S01798-10 S01799-10 168 p. 141) Remove the front side cover. ( 3. 4. p.
SERVICE WORK ON THE CHASSIS 13 – Remove screw – Raise the fuel tank cover at the rear and take it off in a forward direction. 5.
13 SERVICE WORK ON THE CHASSIS 13.26 Installing the fuel tank cover Main work – Position the fuel tank cover. Holding lug 1 engages under the fuel tank 2. Info Pay attention to the sealing lip and the bleeder hose. S01802-10 – Mount and tighten screw 3. Guideline Screw, cover part S01800-11 170 M5 3.5 Nm (2.
SERVICE WORK ON THE CHASSIS 13 – Mount and tighten screw 4. Guideline Screw, cover part – M6 Mount and tighten screw 6 Nm (4.4 lbf ft) 5. Guideline Screw, cover part M5 3.5 Nm (2.58 lbf ft) S01799-11 – Mount and tighten screw 6. Guideline Screw, cover part – M6 Mount and tighten screw 6 Nm (4.4 lbf ft) 7. Guideline Screw, cover part M5 3.5 Nm (2.58 lbf ft) S01798-11 Finishing work – Install the front side cover. ( – Mount the seat. ( p. 157) p.
13 SERVICE WORK ON THE CHASSIS 13.27 Removing the windshield – Remove screws – Position windshield – Mount and tighten screws 1 with rubber bushing and windshield 2. S01803-10 13.28 Installing the windshield 1. 2 with the rubber bushings. Guideline Screw, wind shield A00225-10 172 M5 3.5 Nm (2.
SERVICE WORK ON THE CHASSIS 13 13.29 Removing the engine guard – Remove screws – Position engine guard and tighten. 1 with bushings and engine guard 2. S01804-10 13.30 Installing the engine guard 1, mount screws 2 with bushings Guideline Screw, engine guard M6 10 Nm (7.
13 SERVICE WORK ON THE CHASSIS 13.31 Removing the crash bar – Remove fittings 1. – Remove screws 2 and take off the clamp halves.
SERVICE WORK ON THE CHASSIS 13 – – 3. Remove screw 4. – Take off the left crash bar. – Remove screws Remove screw D03198-10 5 and take off the clamp halves.
13 SERVICE WORK ON THE CHASSIS – – 6. Remove screw 7. – Take off the right crash bar. – Position the right crash bar with the frame protector. Remove screw D03200-10 13.32 Installing the crash bar The tank holding rubber should be correctly positioned on the fuel tank. Info Cover the components to protect them against damage. – 1 but do not tighten yet. Guideline D03200-11 Remaining screws, chassis – 176 Mount screw Mount screw M10 2 but do not tighten yet. 45 Nm (33.
SERVICE WORK ON THE CHASSIS 13 Guideline Remaining screws, chassis – Mount screws M6 10 Nm (7.4 lbf ft) 3 with clamp halves, but do not tighten yet. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) D03199-11 – Position the left crash bar with the frame protector. The tank holding rubber should be correctly positioned on the fuel tank. Info Cover the components to protect them against damage. – D03198-11 Mount screw 4 but do not tighten yet.
13 SERVICE WORK ON THE CHASSIS – Mount screw 5 but do not tighten yet. Guideline Remaining screws, chassis – Mount screws M6 10 Nm (7.4 lbf ft) 6 with clamp halves, but do not tighten yet. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) D03197-11 – Mount and tighten fittings 7. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) The crash bars are equally aligned with each other. – D03196-11 178 Tighten all the screws of the crash bar.
SERVICE WORK ON THE CHASSIS 13 Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Remaining screws, chassis M10 45 Nm (33.
14 BRAKE SYSTEM 14.1 Anti-lock braking system (ABS) 1 3 0 2 0 The ABS module , consisting of a hydraulic unit, an ABS control unit, and a return pump, is located under the seat. One wheel speed sensor is located in each case on the front and the rear wheel. 2 Warning Danger of accidents Changes to the vehicle impair the function of the ABS. 0 1 0 2 401662-01 180 – Only allow the rear wheel to spin with the front brake applied away from public road traffic if the ABS is switched off.
BRAKE SYSTEM 14 Note Voiding of the government approval for road use and the insurance coverage If the ABS is switched off completely, the vehicle's approval for road use is invalidated. – Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off completely. ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.
14 BRAKE SYSTEM Info In the Offroad ABS mode, the rear wheel may lock and there is a risk of falling. The ABS operates with two independent brake circuits (front and rear brakes). When the ABS control unit detects a locking tendency in a wheel, ABS begins regulating the brake pressure. The control function causes a slight pulsing of the hand and foot brake levers. The ABS warning lamp must light up after the ignition is switched on and go out after starting off.
BRAKE SYSTEM 14 14.2 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple points for the dimension . A Info Wear will reduce the thickness of the brake disc at contact surface of the brake linings. 1 Brake discs - wear limit 400618-10 » – front 4 mm (0.16 in) rear 4.
14 BRAKE SYSTEM » 14.3 If the brake disc exhibits damage, cracking, or deformation: – Change the front brake discs. – Change the rear brake disc. Checking the front brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
BRAKE SYSTEM 14 – Move the brake reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in brake fluid reservoir » If an air bubble is visible at the marking – Add front brake fluid. ( 1. A: p. 185) S01805-10 14.4 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
14 BRAKE SYSTEM Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin.
BRAKE SYSTEM 14 Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. Preparatory work – Check the front brake linings. ( p. 188) Main work – Move the brake reservoir mounted on the handlebar to a horizontal position. – – – 1. Take off cover 2 with membrane 3. Add brake fluid to level A.
14 BRAKE SYSTEM Info Clean up overflowed or spilled brake fluid immediately with water. 14.5 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc.
BRAKE SYSTEM 14 – Check all brake linings on both brake calipers to ensure they have the minimum thickness . A Minimum thickness » S00957-10 Change the front brake linings. Check all brake linings on both brake calipers for damage and cracking. » If there is damage or cracking: – 14.6 ≥ 1 mm (≥ 0.04 in) If the minimum thickness is less than specified: – – A Change the front brake linings.
14 BRAKE SYSTEM Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Check the brake fluid level in brake fluid reservoir » If the fluid level reaches the MIN marking – Add rear brake fluid. ( 1. A : p. 190) S01807-10 14.
BRAKE SYSTEM 14 Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin.
14 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. Preparatory work – Check the rear brake linings. ( p. 193) Main work – Remove screw cap – 1 with membrane 2. Add brake fluid up to MAX marking A. Brake fluid DOT 4 / DOT 5.1 ( – Mount and tighten screw cap p.
BRAKE SYSTEM 14 14.8 Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc.
15 WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( – Remove the bottom triple clamp cover. ( – Lift the motorcycle with the front lifting gear. ( p. 134) p. 154) p. 135) Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. – V00006-10 194 Remove screw hole.
WHEELS, TIRES 15 – Remove screws – Press back the brake linings by slightly tilting the brake calipers laterally on the brake disc. – Pull the brake calipers carefully back from the brake discs and hang to the side loosely. 3 from both brake calipers. Info Do not operate the hand brake lever if the brake calipers have been removed. S00959-10 – – – 4 by several rotations. Loosen screws 5. Press on screw 4 to push the wheel spindle out of the axle Loosen screw clamp. – Remove screw 4.
15 WHEELS, TIRES Info Do not actuate the hand brake lever when the front wheel is removed. – Remove spacers 6. H02027-10 15.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. 196 – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary.
WHEELS, TIRES 15 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Change front wheel bearing. Clean and grease shaft seal rings of the spacers. Long-life grease ( 1 and contact surfaces A p. 300) H02026-10 – Insert wide spacer 2 on the left in the direction of travel. Info B Arrow indicates the direction of travel of the front wheel. The ABS sensor wheel is on the left viewed in the direction of travel.
15 WHEELS, TIRES Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. S00962-10 – – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Clean and lightly grease screw Long-life grease ( 3 and wheel spindle 4. p. 300) – Jack up the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw 3. Guideline Screw, front wheel spindle 198 M25x1.5 45 Nm (33.
WHEELS, TIRES 15 – Position the brake calipers. The brake linings are correctly positioned. – Mount screws yet. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in the activated position. 5 on both brake calipers, but do not tighten The brake calipers straighten. S00959-11 – Tighten screws 5 on both brake calipers. Guideline Screw, front brake caliper M10 45 Nm (33.
15 WHEELS, TIRES – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws 8. Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) K00540-11 Finishing work – Install the bottom triple clamp cover. ( 15.3 p. 155) Removing the rear wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( 200 p.
WHEELS, TIRES 15 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. S01832-10 – Remove screw hole.
15 WHEELS, TIRES – Remove nut – Pull out wheel spindle to be pushed forward. – Push the rear wheel forward as far as possible. Take the chain off the rear sprocket and place it on chain sprocket guard . 3. Remove chain adjuster 4. S01831-10 5 far enough to allow the rear wheel 6 Warning Danger of accidents Damaged brake discs reduce the braking effect. – S01833-10 – 202 Always lay the wheel down in such a way that the brake disc is not damaged. Hold the rear wheel and remove the wheel spindle.
WHEELS, TIRES 15 Info Do not operate the foot brake when the rear wheel is removed. – 15.4 Remove spacer 7. Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
15 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Change the rear wheel bearing. Clean and grease shaft seal ring the spacer. Long-life grease ( – D03109-10 S01834-10 204 1 and contact surface A of p. 300) Clean and lightly grease wheel spindle and nut. Long-life grease ( p. 300) – Mount the damping rubber pieces and rear sprocket carrier on the rear wheel.
WHEELS, TIRES 15 – Push the wheel spindle in all the way and mount chain adjuster and nut . 4 5 Info Mount chain adjusters tion. – S01835-10 3 and 4 in the same posi- Make sure that the chain adjusters are fitted correctly on the adjusting screws. 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 markings . B – Tighten nut 5. Guideline Nut, rear wheel spindle M25x1.5 90 Nm (66.
15 WHEELS, TIRES – – 6 in the hole. Mount and tighten screw 7. Position wheel speed sensor Guideline Screw, rear wheel speed sensor – S01830-11 M6 10 Nm (7.4 lbf ft) Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 134) 15.
WHEELS, TIRES 15 Main work – Check the damping rubber pieces age and wear. » 1 of the rear hub for dam- If the damping rubber pieces of the rear hub are damaged or worn: – Change all the damping rubber pieces of the rear hub. S01836-10 – Lay the rear wheel on a workbench with the rear sprocket facing upward and insert the wheel spindle in the hub. – Check the rear sprocket play A. Info Measure the play on the outside of the rear sprocket. ≤ 5 mm (≤ 0.
15 WHEELS, TIRES – 15.6 Remove the rear of the motorcycle from the lifting gear. ( p. 134) Checking the tire condition Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
WHEELS, TIRES 15 Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened. – Run in new tires with moderate riding at alternating angles. Running-in phase 200 km (124 mi) Info Tire type, tire condition, and tire pressure influence the braking and handling characteristics of the vehicle. Worn tires are particularly unfavorable on wet surfaces. – Check the front and rear tires for cuts, run-in objects, and other damage.
15 WHEELS, TIRES – Check the tire age. Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. H01144-10 » If the tires are more than 5 years old: – 15.7 Change the tires.
WHEELS, TIRES 15 – Remove the protection cap. – Check the tire pressure when the tires are cold. Tire pressure, solo / with passenger / full payload » 15.8 – 2.6 bar (38 psi) rear: with cold tires 2.9 bar (42 psi) If the tire pressure does not meet specifications: – 400695-01 front: with cold tires Correct the tire pressure. Mount the protection cap.
15 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ. 400694-01 You should hear a high note. » If the spoke tension differs: – 212 Correct the spoke tension.
WHEELS, TIRES 15 15.9 Using tire repair spray Warning Danger of accidents Incorrect use of tire repair spray will result in the repaired tire losing pressure. Tire repair spray cannot be used for all types of damage. – Observe the instructions and specifications of the manufacturer of the tire repair spray. – After repairing a tire with tire repair spray, ride slowly and carefully. – Ride no further than to the nearest workshop and have the tire changed.
15 WHEELS, TIRES 15.10 Tubeless tire system This vehicle uses a tubeless tire system in which a rim seal band is used instead of the conventional tube. The advantages of the tubeless system lie in the absence of danger from a faulty tube. This greatly reduces the risk of a sudden loss in pressure. The masses and moments of inertia of these wheels are smaller than in conventional spoke wheels with a tube. This results in better handling and riding comfort.
ELECTRICAL SYSTEM 16 16.1 Daytime running light Warning Danger of accidents When visibility is poor, the daytime running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain. – Ensure that the appropriate type of lighting is always selected.
16 ELECTRICAL SYSTEM light. When the daytime running light is switched off, it serves as a position light. 16.2 Removing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. – Keep sparks or open flames away from the 12 V battery. – Only charge 12 V batteries in well-ventilated rooms.
ELECTRICAL SYSTEM 16 Main work – Pull locking mechanism 1 in the direction of the arrow. – Fold open cover – Disconnect both negative cables 2. S01811-10 – – 3 from the 12-V battery. Disconnect both positive cables 4 from the 12-V battery. Take the 12-V battery and battery case 5 out of the battery compartment.
16 ELECTRICAL SYSTEM 16.3 Installing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. – Keep sparks or open flames away from the 12 V battery. – Only charge 12 V batteries in well-ventilated rooms.
ELECTRICAL SYSTEM 16 Main work – Position the 12-V battery in battery case 1. Guideline The even side of the battery case must be opposite the poles. S01812-11 – Position the 12-V battery with the battery case in the battery compartment. – Position both positive cables screw. 2 and mount and tighten the Guideline Screw, battery terminal – M6 Position the negative cable screw. 4.5 Nm (3.32 lbf ft) 3 and mount and tighten the Guideline Screw, battery terminal M6 4.5 Nm (3.
16 ELECTRICAL SYSTEM – Close cover 4 and gently push down. The cover engages with an audible click. S01813-10 Finishing work – Mount the seat. ( – 220 p. 141) Set the time and date.
ELECTRICAL SYSTEM 16 16.4 Charging the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. – Keep sparks or open flames away from the 12 V battery. – Only charge 12 V batteries in well-ventilated rooms.
16 ELECTRICAL SYSTEM Info Even if there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the capacity of the 12-V battery.
ELECTRICAL SYSTEM 16 Main work – Pull locking mechanism 1 in the direction of the arrow. – Fold open cover – Disconnect both negative cables from the 12-V battery to avoid damaging the onboard electronics. 2.
16 ELECTRICAL SYSTEM – Connect the battery charger to the 12-V battery. Switch on the battery charger. Battery charger (58429074000) Info You can also use the battery charger to test the opencircuit voltage and starting ability of the 12-V battery, and to test the alternator. In addition, you cannot overcharge the 12-V battery with this device. Charge the 12-V battery to a maximum of 10 % of the capacity specified on the battery housing.
ELECTRICAL SYSTEM 16 – Connect both negative cables 3 to the 12-V battery. Guideline Screw, battery terminal M6 4.5 Nm (3.32 lbf ft) S01868-10 – Close cover 4 and gently push down. The cover engages with an audible click. S01813-10 Finishing work – Mount the seat. ( – p. 141) Set the time and date.
16 ELECTRICAL SYSTEM 16.5 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF . – Remove the seat. ( Main work – Remove screws – S01815-10 226 p. 141) 1. Raise rear fairing 2 slightly.
ELECTRICAL SYSTEM 16 – Take off protection caps 3. – Remove faulty main fuse 4. S01816-10 Info You can recognize a faulty fuse by a burned-out fuse wire . A spare fuse is located in the starter relay. The main fuse protects all power consumers of the vehicle. A 5 A00221-10 – Install a new main fuse. Fuse (58011109130) ( p. 286) – Check that the electrical system is functioning properly. – Mount the protection caps.
16 ELECTRICAL SYSTEM Tip Insert a new spare fuse into the starter relay to have it available when needed. – Position rear fairing – Mount and tighten screws 2. 1. Guideline Screw, cover part M5 S01815-10 Finishing work – Mount the seat. ( – 228 p. 141) Set the time and date. 3.5 Nm (2.
ELECTRICAL SYSTEM 16 16.6 Changing the fuses in the fuse box Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF . – Remove the seat. ( p.
16 ELECTRICAL SYSTEM Main work – Open fuse box cover 1. S01869-10 – Check the fuses. Info You can recognize a faulty fuse by a burned-out fuse wire . A – S01819-10 230 Remove the faulty fuse.
ELECTRICAL SYSTEM 16 Guideline Fuse res - 10 A - spare fuses Fuse 1 - 10 A - power supply for control units and components Fuse 2 - 10 A - permanent positive for auxiliary equipment (ACC1) Fuse 3 - 15 A - ABS hydraulic unit Fuse 4 - 25 A - ABS return pump Fuse 5 - not assigned – Use spare fuses with the correct rating only. Fuse (58011109110) ( p. 286) Fuse (58011109115) ( p. 286) Fuse (58011109125) ( p. 286) Tip Insert a spare fuse so that it is available if needed.
16 ELECTRICAL SYSTEM 16.7 Removing the headlight mask with the headlight Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF . – Remove the seat. ( – Remove the front side cover. ( p. 156) – Remove the fuel tank cover. ( p. 168) – Remove the mask spoiler. ( p. 158) – Remove the windshield. ( p. 172) Main work – Remove screws – S01820-10 232 p. 141) 1. Take off the headlight mask toward the front.
ELECTRICAL SYSTEM 16 – Disconnect plug-in connector – Place the headlight mask onto a soft cloth so that the headlight is not damaged. 2. S01821-10 16.8 Installing the headlight mask with the headlight Main work – Connect plug-in connector 1 of the headlight. – Check that the lighting is functioning properly. – Position the headlight mask.
16 ELECTRICAL SYSTEM – Mount and tighten screws 2. Guideline Screw, headlight M6 5 Nm (3.7 lbf ft) S01820-11 234 Finishing work – Install the windshield. ( p. 172) – Install the mask spoiler. ( p. 162) – Install the fuel tank cover. ( p. 170) – Install the front side cover. ( p. 157) – Mount the seat. ( – Check the headlight setting. ( p. 141) p.
ELECTRICAL SYSTEM 16 16.9 Changing the low beam bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. – Do not touch the bulbs with your bare hands. Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF . – Remove the seat. ( – Remove the front side cover. ( p. 156) – Remove the fuel tank cover.
16 ELECTRICAL SYSTEM Main work – Remove cable tie(s) – 1. Push headlight bulb 2 lightly into the bulb socket, turn it all the way counterclockwise, and pull it out. – Unplug connector 3. – Plug in connector 3 into the new headlight bulb. S01822-10 Low beam (H11/socket PGJ19-2) ( – Position headlight bulb the way clockwise. p. 286) 2 into the bulb socket and turn it all The headlight bulb is locked into the bulb socket. – Mount cable tie(s) 1.
ELECTRICAL SYSTEM 16 16.10 – Mount the seat. ( – Check the headlight setting. ( p. 141) p. 240) Changing the high beam bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. – Do not touch the bulbs with your bare hands. Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF . – Remove the seat.
16 ELECTRICAL SYSTEM Main work – Push headlight bulb lightly into the bulb socket, turn it all the way counterclockwise, and pull it out. 1 – Unplug connector – Plug connector 2. S01824-10 2 into the new headlight bulb. High beam (H11/socket PGJ19-2) ( – Position headlight bulb the way clockwise. p. 287) 1 into the bulb socket and turn it all The headlight bulb is locked into the bulb socket. S01825-10 Finishing work – Install the headlight mask with the headlight.
ELECTRICAL SYSTEM 16 16.11 – Mount the seat. ( – Check the headlight setting. ( p. 141) p. 240) Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. – Do not touch the bulbs with your bare hands. – Remove the screw on the front of the turn signal housing.
16 ELECTRICAL SYSTEM – Position the turn signal glass. Info Insert holding lug 16.12 A into cut-out B. – Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly. – Park the vehicle on a horizontal surface in front of a lightcolored wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance Checking the headlight setting B under the first marking.
ELECTRICAL SYSTEM 16 The light-dark boundary must be exactly on the lower marking when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: – 16.13 Adjust the headlight range. ( p. 241) Adjusting the headlight range Preparatory work – Check the headlight setting. ( – p. 240) Remove the bottom triple clamp cover. ( Main work – Turn adjusting screw p.
16 ELECTRICAL SYSTEM – Set the headlight to marking B. Guideline The light-dark boundary must lie exactly on lower marking when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. B 400726-11 Finishing work – Install the bottom triple clamp cover. ( 16.14 p.
ELECTRICAL SYSTEM 16 Loss of a black ignition key (additional black ignition keys are available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Press the emergency OFF switch to the position ON – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the position ON . – Switch off the ignition by turning the orange programming key to the position OFF .
16 ELECTRICAL SYSTEM – Switch on the ignition by turning the orange programming key to the position ON . The immobilizerindicator lamp flashes according to the number of functional black ignition keys including the orange programming key. In this case, it flashes twice. – Switch off the ignition by turning the orange programming key to the position OFF . – Pull out the orange programming key. The lost black ignition key is deactivated. The existing black ignition key is reactivated.
ELECTRICAL SYSTEM 16 – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the position ON . – Switch off the ignition by turning the orange programming key to the position OFF . – Switch on the ignition by turning the orange programming key to the position ON . Immobilizer indicator lamp lights up.
16 ELECTRICAL SYSTEM – Switch off the ignition by turning the orange programming key to the position OFF . – Pull out the orange programming key. – Insert the black ignition key in the ignition lock. – Switch on the ignition by turning the black ignition key to the position ON . – Switch off the ignition by turning the black ignition key to the position OFF . – Remove the black ignition key.
ELECTRICAL SYSTEM 16 Info Activation of the ignition key is finished. To activate four black ignition keys: – Press the emergency OFF switch to the position ON . – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the position ON . Immobilizer indicator lamp lights up. – Switch off the ignition by turning the orange programming key to the position OFF . – Pull out the orange programming key.
16 ELECTRICAL SYSTEM Info As soon as the fourth black ignition key has been activated, programming is finished. 16.15 Diagnostics connector Diagnostics connector F00730-10 248 1 is located under the seat.
ELECTRICAL SYSTEM 16 16.16 Front ACC1 and ACC2 Installation location – The front power supplies ACC1 behind the headlight. 1 and ACC2 2 are located Info A00223-10 16.17 The power supplies are protected by a fuse, however this fuse also protects other power consumers. The maximum continuous load is therefore significantly lower than the value of the fuse. Do not use a stronger fuse. ACC1 and ACC2 rear Installation location – The rear power supplies ACC1 under the luggage rack plate.
17 COOLING SYSTEM 17.1 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. – Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
COOLING SYSTEM 17 – Park the motorcycle on a horizontal surface. – Check the coolant level in the compensating tank 1. The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! S01827-10 – » Add coolant/bleed the cooling system. If the coolant in the compensating tank is not at the required level, but the tank is not empty: – Correct the coolant level in the compensating tank. ( p.
17 COOLING SYSTEM 17.2 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. – Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
COOLING SYSTEM 17 Info Only disassemble the right-hand side. Main work – Remove cover 1 of the compensating tank. S01828-10 – Add coolant until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX. Coolant ( – p. 296) Mount the cover of the compensating tank. S01827-01 Finishing work – Install the front side cover. ( p.
18 TUNING THE ENGINE 18.
TUNING THE ENGINE 18 18.2 Traction control (TC) The traction control (TC) lowers the engine torque in case of loss of traction in the rear wheel. Depending on the motorcycle traction control setting, a slight slip on the rear wheel may be desirable. Example: offroad. Info L01436-10 When traction control is switched off, the rear wheel may spin during high acceleration and on surfaces with low grip. After the ignition is switched back on, traction control is enabled again.
19 SERVICE WORK ON THE ENGINE 19.1 Checking the engine oil level Info Oil consumption depends on the riding style and the operating conditions. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level in the engine oil level viewer. Info After switching off the engine, wait one minute before checking the level.
SERVICE WORK ON THE ENGINE 19 » When the engine oil level is in area level viewer: – 19.2 Add engine oil. ( C of the engine oil p. 264) Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. – In the event of scalding, rinse the area affected immediately with lukewarm water.
19 SERVICE WORK ON THE ENGINE Main work – Stand the motorcycle on its side stand on a horizontal surface. – Place an appropriate container under the engine. – Remove oil drain plugs screens. – Remove screws ring. 1 with the magnets, O-rings, and oil S00333-10 S00334-10 258 2.
SERVICE WORK ON THE ENGINE 19 – Pull oil filter 4 out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. – Insert new oil filter S01838-10 4. Info Only insert the oil filter by hand. – Lubricate the O-ring of the oil filter cover. Mount oil filter cover .
19 SERVICE WORK ON THE ENGINE – Mount and tighten screws 2. Guideline Remaining engine screws M5 6 Nm (4.4 lbf ft) S00334-11 – 100773-12 260 Thoroughly clean magnets drain plugs.
SERVICE WORK ON THE ENGINE 19 – Mount and tighten oil drain plugs rings, and oil screens. 1 with the magnets, O- Guideline Oil drain plug M20x1.5 20 Nm (14.8 lbf ft) S00333-10 – Have the entire filling quantity available. Engine oil Ambient temperature: ≥ 0 °C (≥ 32 °F) Engine oil Ambient temperature: < 0 °C (< 32 °F) S01840-10 3.60 l (3.8 qt.) Engine oil (SAE 10W/50) ( p. 297) Engine oil (SAE 5W/40) ( p. 298) – Add the oil quantity quantity in two separate operations.
19 SERVICE WORK ON THE ENGINE Engine oil (1st partial quantity) approx. Ambient temperature: ≥ 0 °C (≥ 32 °F) 3.0 l (3.2 qt.) Engine oil (1st partial quantity) approx. Ambient temperature: < 0 °C (< 32 °F) – Mount screw plug Engine oil (SAE 10W/50) ( p. 297) Engine oil (SAE 5W/40) ( p. 298) 5. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. 262 – Always make sure there is sufficient ventilation when running the engine.
SERVICE WORK ON THE ENGINE 19 – Remove the screw plug and add the second partial quantity up to the upper marking on the engine oil level viewer. A Engine oil (2nd partial quantity) approx. Ambient temperature: ≥ 0 °C (≥ 32 °F) 0.60 l (0.63 qt.) Engine oil (2nd partial quantity) approx. Ambient temperature: < 0 °C (< 32 °F) S01857-10 – Engine oil (SAE 10W/50) ( p. 297) Engine oil (SAE 5W/40) ( p. 298) Mount the screw plug.
19 SERVICE WORK ON THE ENGINE Finishing work – Check the engine oil level. ( – 19.3 Install the engine guard. ( p. 256) p. 173) Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. The engine may be damaged if the engine oil level is too high. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. – 264 Check the engine oil level. ( p.
SERVICE WORK ON THE ENGINE 19 Main work – Remove screw plug 1. S01840-11 – Add engine oil to upper marking viewer. A on the engine oil level Condition Ambient temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 297) Condition Ambient temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( S00329-10 p. 298) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. KTM recommends changing the engine oil. – Mount the screw plug.
19 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space. Start the engine and check for tightness. Finishing work – Check the engine oil level. ( 266 p.
CLEANING, CARE 20 20.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. – Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
20 CLEANING, CARE – Close off the exhaust system to keep water from entering. – Remove loose dirt first with a soft jet of water. – Spray heavily soiled parts with a normal commercial motorcycle cleaner and then brush off with a soft brush. Motorcycle cleaner ( p. 300) Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water.
CLEANING, CARE 20 – After cleaning, ride the vehicle a short distance until the engine warms up. Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate. – Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain.
20 CLEANING, CARE – Treat the plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 301) – Oil the ignition and steering lock, tank lock, and seat lock. Universal oil spray ( 20.2 p. 301) Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt.
CLEANING, CARE 20 – Clean the motorcycle. ( – Clean the brakes. p. 267) Info After EVERY trip on salted roads, thoroughly clean the brake calipers and brake linings, after they have cooled down and without removing them, with cold water and dry them carefully. After riding on salted roads, thoroughly clean the motorcycle with cold water and dry it well. 401060-01 – Treat the engine, the link fork, and all other bare or zinc-plated parts (except the brake discs) with a wax-based corrosion inhibitor.
21 STORAGE 21.1 Storage Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed. Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.
STORAGE 21 – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. – Cover the motorcycle with a tarp or cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 21.
22 TROUBLESHOOTING Faults Possible cause Action Combination instrument shows nothing on the display Fuse 1 blown – Change the fuses in the fuse box. ( p. 229) Main fuse burned out – Change the main fuse. ( p. 226) 12-V battery discharged – Charge the 12-V battery. ( – Check the open-circuit current. Ignition and steering lock is faulty – Check the ignition and steering lock. Emergency OFF switch is off – Press the emergency OFF switch to the position ON .
TROUBLESHOOTING 22 Faults Possible cause Action Engine turns only if the clutch lever is drawn The vehicle is in gear – Shift the transmission into neutral Faulty safety starting system – Read out the fault memory using the KTM diagnostics tool. Engine turns although a gear is engaged Faulty safety starting system – Read out the fault memory using the KTM diagnostics tool.
22 TROUBLESHOOTING Faults Possible cause Action High oil consumption Engine oil level too high – Check the engine oil level. ( Engine oil too thin (low viscosity) – Change the engine oil and oil filter and clean the oil screens. ( p. 257) A power consumer is connected to the socket/ACC1. – Disconnect the power consumer from the socket/ACC1. – Charge the 12-V battery. The hazard warning flasher is switched on – Switch off the hazard warning flasher. – Charge the 12-V battery.
TECHNICAL DATA 23 23.1 Engine Design 2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled Displacement 1,050 cm³ (64.08 cu in) Stroke 63 mm (2.48 in) Bore 103 mm (4.06 in) Compression ratio 13.0:1 Idle speed 1,280 … 1,480 rpm Control DOHC, 4 valves per cylinder, chain-driven Valve - valve plate diameter Intake 42 mm (1.65 in) Exhaust 34 mm (1.34 in) Valve clearance Exhaust at: 20 °C (68 °F) 0.25 … 0.30 mm (0.0098 … 0.0118 in) Intake at: 20 °C (68 °F) 0.10 … 0.15 mm (0.
23 TECHNICAL DATA Engine lubrication Pressure circulation lubrication with three rotary pumps Primary transmission 40:76 Clutch Antihopping clutch in oil bath/hydraulically operated Transmission 6-gear transmission, claw shifted Transmission ratio 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Altern
TECHNICAL DATA 23 Cold start device 23.2 Starter motor Engine tightening torques Screw, damping plate EJOT ALtracs® M6x14 10 Nm (7.4 lbf ft) Loctite®243™ Screw, retaining bracket, valve cover, rear EJOT ALtracs® M6x10 10 Nm (7.4 lbf ft) Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) Oil nozzle M5 2 Nm (1.5 lbf ft) Loctite®243™ Remaining engine screws M5 6 Nm (4.4 lbf ft) Screw, bearing retainer M5 6 Nm (4.
23 TECHNICAL DATA Freewheel ring bolt M6 – 10.9 15 Nm (11.1 lbf ft) Loctite® 648™ Nut, cylinder head M6 9 Nm (6.6 lbf ft) Plug, vacuum connection M6 5 Nm (3.7 lbf ft) Loctite®243™ Remaining engine screws M6 10 Nm (7.4 lbf ft) Screw, camshaft bearing support M6 – 10.9 10 Nm (7.4 lbf ft) Screw, clutch cover M6 10 Nm (7.4 lbf ft) Screw, clutch spring M6 12 Nm (8.9 lbf ft) Screw, engine case M6x60 10 Nm (7.4 lbf ft) Screw, engine case M6x80 10 Nm (7.
TECHNICAL DATA 23 Screw, stator M6 10 Nm (7.4 lbf ft) Loctite®243™ Screw, valve cover M6 10 Nm (7.4 lbf ft) Screw, water pump cover M6 10 Nm (7.4 lbf ft) Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite®243™ Stud, timing chain shaft M6 8 Nm (5.9 lbf ft) Vacuum connection M6 5 Nm (3.7 lbf ft) Nozzle 100 M6x0.75 4 Nm (3 lbf ft) Loctite®243™ Plug, crankshaft retainer M8 15 Nm (11.1 lbf ft) Screw, camshaft bearing support M8 – 10.9 Step 1 10 Nm (7.4 lbf ft) Step 2 18 Nm (13.
23 TECHNICAL DATA Screw, timing chain guide rail M8 15 Nm (11.1 lbf ft) Loctite®243™ Screw, timing chain tensioning rail M8 15 Nm (11.1 lbf ft) Loctite®243™ Stud, exhaust flange M8 10 Nm (7.4 lbf ft) Screw, engine bearer M10 45 Nm (33.2 lbf ft) Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) Plug, cam lever axis M10x1 15 Nm (11.1 lbf ft) Plug, clutch lubrication M10x1 10 Nm (7.4 lbf ft) Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.
TECHNICAL DATA 23 Cylinder head screw M11x1.5 Tightening sequence: Using a crisscross pattern Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° Step 4 90° Lubricated with engine oil Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) Screw, rotor Expansion screw M12x1.5 115 Nm (84.8 lbf ft) Spark plug M12x1.5 18 Nm (13.3 lbf ft) Nut of engine sprocket M20x1.5 100 Nm (73.8 lbf ft) Loctite®243™ Oil drain plug M20x1.5 20 Nm (14.8 lbf ft) Nut, inner clutch hub M22x1.
23 TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil Ambient temperature: ≥ 0 °C (≥ 32 °F) 3.60 l (3.8 qt.) Engine oil (SAE 10W/50) ( p. 297) Engine oil Ambient temperature: < 0 °C (< 32 °F) 23.3.2 2.40 l (2.54 qt.) Coolant ( p. 296) 23 l (6.1 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 299) Fuel Total fuel tank capacity, approx. Fuel reserve, approx. 284 p. 298) Coolant Coolant 23.3.3 Engine oil (SAE 5W/40) ( 3.5 l (3.7 qt.
TECHNICAL DATA 23 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powder-coated Fork WP Suspension 4860 ROTA SPLIT Shock absorber WP Suspension 4618 DCC PA Suspension travel front 220 mm (8.66 in) rear 220 mm (8.66 in) Brake system front Double disc brake with radially mounted four-piston brake calipers, floating brake discs rear Single disc brake with dual-piston brake caliper, floating brake disc Brake discs - diameter front 320 mm (12.6 in) rear 267 mm (10.
23 TECHNICAL DATA rear: with cold tires 2.9 bar (42 psi) Secondary drive ratio 17:42 Chain 5/8 x 5/16” (525) X‑ring Steering head angle 64° Wheelbase 1,580 ± 15 mm (62.2 ± 0.59 in) Seat height, unloaded 890 mm (35.04 in) Ground clearance, unloaded 250 mm (9.84 in) Weight without fuel, approx. 214 kg (472 lb.) Maximum permissible front axle load 165 kg (364 lb.) Maximum permissible rear axle load 285 kg (628 lb.) Maximum permissible total weight 450 kg (992 lb.) 23.
TECHNICAL DATA 23 High beam H11/socket PGJ19-2 Position light LED Combination instrument lighting and indicator lamps LED Turn signal RY10W / Socket BAU15s Tail light LED Brake light LED License plate lamp LED 23.6 12 V 55 W 12 V 10 W Tires Front tire Rear tire 90/90 - 21 M/C 54T M+S TL Continental TKC 80 Twinduro 150/70 B 18 M/C 70Q M+S TL Continental TKC 80 Twinduro The tires specified represent one of the possible series production tires.
23 TECHNICAL DATA 23.7 Fork Fork article number 14.18.8Q.25 Fork WP Suspension 4860 ROTA SPLIT Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring preload - Preload Adjuster Comfort 2 turns Standard 5 turns Sport 5 turns Full payload 8 turns Spring length with preload spacer(s) 577 mm (22.72 in) Spring rate Soft 288 5.9 N/mm (33.
TECHNICAL DATA 23 Medium (standard) 6.5 N/mm (37.1 lb/in) Hard 7.0 N/mm (40 lb/in) Fork length 920 mm (36.22 in) Air chamber length 85 Fork oil per fork leg 715 ml (24.17 fl. oz.) 23.8 + 35 −0 mm (3.35 + 1.38 −0 in) Fork oil (SAE 4) (48601166S1) ( p. 298) Shock absorber Shock absorber article number 15.18.7Q.
23 TECHNICAL DATA Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Comfort 2 turns Standard 2 turns Sport 2 turns Full payload 18 turns Spring rate Soft 170 N/mm (971 lb/in) Medium (standard) 180 N/mm (1,028 lb/in) Hard 190 N/mm (1,085 lb/in) Spring length 205 mm (8.07 in) Gas pressure 10 bar (145 psi) Riding sag 55 mm (2.17 in) Static sag 25 mm (0.98 in) Fitted length Shock absorber fluid ( 290 408 mm (16.06 in) p. 298) SAE 2.
TECHNICAL DATA 23 23.9 Chassis tightening torques Nut, valve ISO 10V2 12 Nm (8.9 lbf ft) Loctite®2701™ Screw, combination switch, left M4 2 Nm (1.5 lbf ft) Screw, side stand switch M4 2 Nm (1.5 lbf ft) Rear fairing screw M5x12 3.5 Nm (2.58 lbf ft) Rear fairing screw M5x17 3.5 Nm (2.58 lbf ft) Remaining nuts, chassis M5 5 Nm (3.7 lbf ft) Remaining screws, chassis M5 5 Nm (3.7 lbf ft) Screw brake line holder on frame M5 2 Nm (1.
23 TECHNICAL DATA Screw, rear wheel speed sensor cable guide M5 3 Nm (2.2 lbf ft) Screw, wind shield M5 3.5 Nm (2.58 lbf ft) Spoke nipple M5 5 Nm (3.7 lbf ft) Ground fitting on frame M6 6 Nm (4.4 lbf ft) Nut, ABS module fastening M6 8 Nm (5.9 lbf ft) Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Screw, angle sensor M6 6 Nm (4.4 lbf ft) Loctite®243™ Screw, ball joint of push rod on foot brake cylinder M6 10 Nm (7.
TECHNICAL DATA 23 Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™ Screw, front wheel speed sensor M6 10 Nm (7.4 lbf ft) Screw, fuel pump M6 6 Nm (4.4 lbf ft) Screw, fuel tank M6 10 Nm (7.4 lbf ft) Screw, fuel tap M6 6 Nm (4.4 lbf ft) Screw, headlight M6 5 Nm (3.7 lbf ft) Screw, lower rear panel M6 6 Nm (4.4 lbf ft) Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Screw, rear brake disc M6 Loctite®243™ 14 Nm (10.
23 TECHNICAL DATA Screw, fork stub M8 15 Nm (11.1 lbf ft) Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite®243™ Screw, handle bar end hand guard M8 25 Nm (18.4 lbf ft) Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) Screw, ignition lock (tamper-proof screw) M8 25 Nm (18.4 lbf ft) Screw, rear footrest bracket M8 Loctite®243™ 25 Nm (18.4 lbf ft) Loctite®243™ Screw, steering damper M8 25 Nm (18.4 lbf ft) Loctite®243™ Screw, steering damper clamp M8 12 Nm (8.
TECHNICAL DATA 23 Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite®243™ Screw, side stand bracket M10 45 Nm (33.2 lbf ft) Loctite®243™ Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) Nut, rear sprocket screw M10x1.25 50 Nm (36.9 lbf ft) Loctite®243™ Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Screw, bottom shock absorber M14x1.5 80 Nm (59 lbf ft) Screw, top shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased Thread greased Nut, fork pivot M19x1.5 130 Nm (95.
24 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX® – Brake Fluid DOT 5.1 Coolant Guideline – Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
SUBSTANCES 24 The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted. The use of premixed coolant is recommended. Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants. Recommended supplier MOTOREX® – COOLANT M3.0 Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA2 ( – SAE ( p. 302) p.
24 SUBSTANCES Engine oil (SAE 5W/40) Standard/classification – JASO T903 MA2 ( – SAE ( p. 302) p. 302) (SAE 5W/40) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Fully synthetic engine oil Recommended supplier MOTOREX® – Power Synt 4T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p.
SUBSTANCES 24 Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g.
25 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier MOTOREX® – Chain Clean Fuel additive Recommended supplier MOTOREX® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX® – Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX® – Moto Shine 300
AUXILIARY SUBSTANCES 25 Preserving materials for paints, metal and rubber Recommended supplier MOTOREX® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX® – Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX® – Chainlube Road Strong Universal oil spray Recommended supplier MOTOREX® – Joker 440 Synthetic 301
26 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
INDEX OF SPECIAL TERMS 27 ABS Anti-lock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces ATIR Automatic Turn Indicator Reset Software, which automatically switches the indicator off according to a time or travel distance counter DRL Daytime Running Light Light, which enhances the visibility of the vehicle during the day but is not focused, and in contrast to low beam does not illuminate the road surface TC Traction
28 LIST OF ABBREVIATIONS Art. no. Article number ca. circa cf. compare e.g. for example etc. et cetera i.a. inter alia no. number poss.
LIST OF SYMBOLS 29 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine. 29.
29 LIST OF SYMBOLS 29.3 Green and blue symbols Green and blue symbols reflect information. The high beam indicator lamp lights up blue – The high beam is switched on. The left turn signal lamp flashes green with a steady rhythmic flash – The left turn signal is switched on. The idle indicator lamp lights up green – The transmission is in neutral. The right turn signal lamp flashes green with a steady rhythmic flash – The right turn signal is switched on.
INDEX rear brake, adding INDEX 1 12-V battery charging . . . . . . . . . . . . . . . . . . . . . . . . . 221 installing . . . . . . . . . . . . . . . . . . . . . . . . . 218 removing . . . . . . . . . . . . . . . . . . . . . . . . . 216 A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 ACC1 front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 ACC2 front . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX service display . . "Set Favorites" . . . "Settings" . . . . . . shift warning light "Shift Light" . . . . "Temp" . . . . . . . "Trip 1" . . . . . . . "Trip 2" . . . . . . . "Warning" . . . . . Clutch fluid level, checking/correcting . . . . . . . . . . 150 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 basic position, adjusting . . . . . . . . . . . . . . . 88 Combination instrument . . . . . . . . . . . . . . . . 59-83 "ABS" . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX Engine running in . . . . . . . . . . . . . . . . . . . . . . . . . 99 Engine guard installing . . . . . . . . . . . . . . . . . . . . . . . . . 173 removing . . . . . . . . . . . . . . . . . . . . . . . . . 173 rebound, adjusting . . . . . . . . . . . . . . . . . . 126 spring pretension, adjusting . . . . . . . . . . . . 127 Fork part number . . . . . . . . . . . . . . . . . . . . . . . 36 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 36 Front fender installing . . . . . . . . .
INDEX G I Grab handles . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Ignition key activating/deactivating . . . . . . . . . . . . . . . . 242 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . 38 basic position, adjusting . . . . . . . . . . . . . . . 89 Handlebar position . . . . . . . . . . . . . . . . . . . . . . 84 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Immobilizer . . . . . . . . .
INDEX Matrix display menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 checks and maintenance measures when preparing for use . . . . . . . . . . . . . . . . . . . 102 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Protective clothing . . . . . . . . . . . . . . . . . . . . . . 24 Motorcycle cleaning . . . . . . . . . . . . . . . . . . . . . lifting with front lifting gear . . . . . . . . raising with the rear lifting gear . . . . .
INDEX Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Service schedule . . . . . . . . . . . . . . . . . . . 120-123 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 basic position, adjusting . . . . . . . . . . . . . . . 94 basic position, checking . . . . . . . . . . . . . . . 93 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Shock absorber . . . . . . . . . . . . . . . . . . . . . . . compression damping . . . . . . . . . . . . . . . .
INDEX Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . 208 Tire pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . 210 Tire repair spray using . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Traction control . . . . . . . . . . . . . . . . . . . . . . . 255 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . 116 Triple clamp cover, bottom installing . . . . . . . . . . . . . . . . . . . . . . . . . 155 removing . . . . . . . . . . . . . . . . .
*3213917en* 3213917en 09/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria http://www.ktm.
