OWNER'S MANUAL 2016 1190 Adventure Art. no.
DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly. DEAR KTM CUSTOMER We wish you a lot of enjoyment in riding this vehicle. Please enter the serial numbers of your vehicle below. Chassis number ( p. 22) Engine number ( p. 23) Key number ( Dealer's stamp 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) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
TABLE OF CONTENTS TABLE OF CONTENTS 1 2 3 4 5 MEANS OF REPRESENTATION ........................................ 8 1.1 Symbols used ...................................................... 8 1.2 Formats used....................................................... 9 SAFETY ADVICE............................................................ 10 2.1 Use definition - intended use .............................. 10 2.2 Safety advice..................................................... 10 2.
TABLE OF CONTENTS 7 6.20 Passenger footrest.............................................. 6.21 Shift lever ......................................................... 6.22 Foot brake lever ................................................. 6.23 Side stand......................................................... 6.24 Center stand (Option: Center stand) ..................... COMBINATION INSTRUMENT ....................................... 7.1 Overview ...........................................................
TABLE OF CONTENTS 10.2 Starting............................................................. 82 10.3 Starting off........................................................ 83 10.4 Shifting, riding .................................................. 83 10.5 Applying the brakes............................................ 87 10.6 Stopping, parking............................................... 89 10.7 Transport .......................................................... 91 10.8 Refueling ..........................
TABLE OF CONTENTS 15.2 Installing the front wheel .............................. 15.3 Removing the rear wheel ............................... 15.4 Installing the rear wheel ................................ 15.5 Checking the rear hub rubber dampers ........... 15.6 Checking the tire condition ............................... 15.7 Checking the tire air pressure............................ 15.8 Checking spoke tension .................................... 16 ELECTRICAL SYSTEM .....................................
TABLE OF CONTENTS 23.7 Fork................................................................ 23.7.1 Option: With EDS ........................................ 23.8 Shock absorber ................................................ 23.8.1 Option: With EDS ........................................ 23.9 Chassis tightening torques ................................ 24 SUBSTANCES ............................................................ 25 AUXILIARY SUBSTANCES ...........................................
1 MEANS OF REPRESENTATION 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop.
1 MEANS OF REPRESENTATION 1.2 Formats used 9 The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.
2 SAFETY ADVICE 2.1 Use definition - intended use 10 KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses. Info The motorcycle is only authorized for operation on public roads in the homologated version. 2.2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully.
2 SAFETY ADVICE 2.3 Degrees of risk and symbols 11 Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
2 SAFETY ADVICE 1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 2.5 12 Safe operation Danger Danger of accidents Danger arising from the rider's judgement being impaired.
2 SAFETY ADVICE 2.6 Protective clothing 13 Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.
2 SAFETY ADVICE 2.9 Owner's Manual 14 It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury. Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
3 IMPORTANT NOTES 3.1 Warranty 15 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 KTM Dealer.net, otherwise any warranty coverage will become void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
3 IMPORTANT NOTES 3.4 Service 16 A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis are properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of components. Using the motorcycle in extreme operating conditions, e.g.
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4 VIEW OF VEHICLE 4.
4 VIEW OF VEHICLE 1 Socket for electrical accessories ( 2 Clutch lever ( 3 Seat lock ( 4 Tool set ( 5 Grab handles ( 6 Luggage rack plate ( p. 41) 7 Passenger footrest ( p. 41) 8 Center stand ( 9 Rider footrests ( 10 Shift lever ( p. 42) 11 Side stand ( p. 43) 12 Engine oil level viewer 13 Fuel cocks ( p. 25) p. 39) p. 40) p. 40) p. 44) p. 70) p. 37) 19 p.
4 VIEW OF VEHICLE 4.
4 VIEW OF VEHICLE 1 Combination switch ( p. 26) 2 Filler cap 3 Ignition/steering lock ( 4 Electric starter button ( 4 Emergency OFF switch ( 5 Throttle grip ( 6 Hand brake lever ( 7 Storage compartment 8 Cooling system compensating tank 9 Foot brake lever ( p. 31) p. 30) p. 30) p. 26) p. 25) p.
5 SERIAL NUMBERS 5.1 Chassis number 22 The chassis number is stamped on the bottom right of the frame behind the steering head. The chassis number is also shown on the type label. 402294-10 5.2 Type label The type label 1 0 402174-10 is on the top right of the frame behind the steering head.
5 SERIAL NUMBERS 5.3 Key number 23 The key number Code number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions. 402240-10 5.4 Engine number The engine number 402296-10 is stamped on the right side of the engine.
5 SERIAL NUMBERS 5.5 Fork part number 24 The fork part number is stamped on the inner side of the fork stub. 402295-10 5.6 Shock absorber article number (Option: With EDS) The shock absorber article number case under the spring.
6 CONTROLS 6.1 Clutch lever 25 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 The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate both the front brake and rear brake at the same time. Info When the ABSmode "offroad" is switched on, only the front brake is activated. When ABS is switched off, only the front brake is activated.
6 CONTROLS 6.3 Throttle grip 26 The throttle grip is fitted on the right side of the handlebar. S00216-10 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. Overview of the left combination switch M00547-10 1 Light switch ( p. 27) 2 Hazard warning flasher switch ( 3 Menu switch ( 4 Turn signal switch ( 5 Horn button ( p. 28) p. 28) p. 29) p.
6 CONTROLS 6.4.2 Light switch 27 The light switch is fitted on the combination switch on the left. Possible states Low beam on – Light switch in position and tail light are switched on. . In this position, the low beam High beam on – Push the light switch to position high beam and the tail light are switched on. . In this position, the Headlight flasher. – Push the light switch into position . M00548-10 6.4.
6 CONTROLS 6.4.4 Menu switch 28 The menu The menu Button Button Button Button switch is fitted in the middle of the left combination switch. buttons are used to control the matrix display on the combination instrument. is the UP button. is the DOWN button. is the SET button. is the BACK button. S00224-11 6.4.5 Turn signal switch The turn signal switch is fitted on the combination switch on the left.
6 CONTROLS 29 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 CONTROLS 6.5 Switches on the right side of the handlebar 6.5.1 Emergency OFF switch 30 The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started. A message appears on the matrix display. Emergency OFF switch on – This position is required for operation; the ignition circuit is closed. S00220-10 6.5.
6 CONTROLS 6.6 Ignition/steering lock 31 The ignition/steering lock is located in front of the upper triple clamp. Info The ignition may only be switched on using a black ignition key. With the orange programming key, you can activate or deactivate the black ignition key. Possible states Ignition off OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The black ignition key can be removed.
6 CONTROLS 32 A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle. The black ignition keys are activated when delivered. Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop; they need to be activated for use. 6.8 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle.
6 CONTROLS 6.9 Unlocking the steering 33 – Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove the key. You can now steer the bike again. 400731-01 6.10 Socket for electrical accessories (Adventure EU/FR/AU/JP) Socket for electrical accessories is fitted to the left of the combination instrument.
6 CONTROLS 34 (1190 Adventure CN) Socket for electrical accessories is fitted to the left of the combination instrument. It is connected to permanent positive and fuse-protected. Socket for electrical accessories Voltage 12 V Maximum current consumption 10 A S00945-10 6.11 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first.
6 CONTROLS 35 – Lift cover of the filler cap and insert ignition key in the fuel tank lock. 602612-10 Note Danger of damage Ignition key breakage. – – – S00351-10 To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced. clockwise. Fold open filler cap .
6 CONTROLS 6.12 Closing the filler cap 36 – – . Turn ignition key clockwise. Fold down filler cap S00352-10 – Push down the filler cap and turn the ignition key lock closes. counterclockwise until the tank Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – S00353-10 – After closing the filler cap, ensure that it is locked properly. Change clothing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.
6 CONTROLS 6.13 Fuel cocks 37 A fuel cock 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. G00588-10 6.14 Possible states • Fuel cocks are closed – A level equalization cannot take place and fuel cannot flow out of the fuel tank. • Fuel cocks are open – A level equalization can take place and fuel can flow out of the fuel tank.
6 CONTROLS 38 (1190 Adventure CN) – Press lock in the direction of the arrow and lift the cover at the same time. S00946-10 6.15 Closing the storage compartment (Adventure EU/FR/AU/JP) – Press cover downward. The lock engages audibly.
6 CONTROLS 39 (1190 Adventure CN) – Press cover downward. The lock engages audibly. S00946-11 6.16 Seat lock (Option: With EDS) The seat lock is located on the left side of the vehicle. It can be unlocked using the ignition key.
6 CONTROLS 6.17 Tool set (Adventure EU/FR/AU/JP) 40 The tool set is located in the storage compartment under the seat. M00549-10 6.18 Grab handles The passenger can hold onto grab handles M00550-10 during the trip.
6 CONTROLS 6.19 Luggage rack plate 41 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 8 kg (18 lb.) Info Note the information provided by the luggage manufacturer. M00550-11 6.20 Passenger footrest The passenger footrests are foldable.
6 CONTROLS 6.21 Shift lever 42 The shift lever is fitted on the left side of the engine. 402299-10 The gear positions can be seen in the figure. The idle position is between the first and second gears.
6 CONTROLS 6.22 Foot brake lever 43 Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. 402301-10 6.23 Side stand The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system. See the instructions in the "Stopping, parking" chapter.
6 CONTROLS 6.24 Center stand (Option: Center stand) 44 In addition to the side stand, the vehicle is equipped with a center stand 402031-10 .
7 COMBINATION INSTRUMENT 7.1 Overview 45 1 Matrix display ( 2 Tachometer p. 46) 3 Shift warning light ( 4 Segment display 5 Indicator lamps ( p. 49) p. 47) 402341-10 7.2 Activation and test Activation The combination instrument is activated when the ignition is switched on. Info The brightness of the displays is controlled by a brightness sensor in the combination instrument.
7 COMBINATION INSTRUMENT 7.3 Matrix display 46 The matrix display is controlled using the menu switch ( p. 28). After the ignition is switched on, the display shows when the next service ( p. 50) is due. If the General warning lamp lights up among the indicator lamps ( p. 47), the corresponding message appears in the matrix display. The SET button is used to confirm receipt of the information and the message is cleared. Messages appear 10 s 401821-01 7.
7 COMBINATION INSTRUMENT 7.5 Indicator lamps 47 Possible states The high beam indicator lamp lights up blue – The high beam is switched on. 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 – Engine oil pressure is too low. 401813-01 The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown on the matrix display.
7 COMBINATION INSTRUMENT 7.6 Message on the matrix display 48 Possible states Engine malfunction – The engine control unit has detected a fault. Visit an authorized KTM workshop. General message – General message on operating safety. Visit an authorized KTM workshop. ABS warning – ABS is not available. Visit an authorized KTM workshop. 401850-01 Motorcycle traction control – The motorcycle traction control is not available. Visit an authorized KTM workshop.
7 COMBINATION INSTRUMENT 49 Battery voltage – The battery voltage is too low. Recharge the battery with a suitable battery charger. Service – A service is due. Contact an authorized KTM workshop. Emergency OFF switch – The emergency OFF switch is off. The messages are displayed in the "Warning" menu. 7.7 Shift warning light The shift warning light flashes or lights up when the transmission should be shifted. In the "Shift Light" menu, the engine speed for the shift warning light can be set.
7 COMBINATION INSTRUMENT The shift warning light always lights up at 7.8 50 6,500 rpm 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. 401821-01 7.9 Matrix display menu 7.9.1 "Favorites" – Press the UP or DOWN button until the "Favorites" menu appears on the matrix display.
7 COMBINATION INSTRUMENT 7.9.2 "Trip 1" – 51 Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display. "Trip 1" shows the distance since the last reset, such as between two refueling stops. "Trip 1" runs continuously and counts the distance up to 9999. "Ø Speed 1" indicates the average speed based on "Trip 1" and "Trip Time 1". "Ø Cons 1" indicates the average fuel consumption based on "Trip 1" and "Trip Time 1".
7 COMBINATION INSTRUMENT 7.9.4 "General Info" – Press the UP oder DOWN button until the "General Info" menu appears on the matrix display. "Air Temp" indicates the ambient air temperature. "Date" indicates the date. "ODO" indicates the total distance covered. "Battery" indicates the battery voltage. "Oil Temp" indicates the engine oil temperature. 401824-01 7.9.
7 COMBINATION INSTRUMENT 53 Guideline Tire air pressure, solo/with passenger/full payload Front: with cold tires 2.4 bar (35 psi) Rear: with cold tires 2.9 bar (42 psi) The "TPMS" menu displays the tire pressure of the front and rear tires. "FW" indicates the tire air pressure at the front. "RW" indicates the tire air pressure at the rear. 7.9.6 "Set Favorites" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Set Favorites" menu appears on the matrix display.
7 COMBINATION INSTRUMENT 7.9.7 "Settings" 54 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 7.9.8 "Warning" Condition • Message or warning – Press the UP or DOWN button until the "Warning" menu appears on the matrix display.
7 COMBINATION INSTRUMENT 7.9.9 "Heating" (optional) 55 – 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 7.9.10 "MTC/ABS" Condition • The vehicle is stationary. – Press theUP or DOWN button until the "MTC"/"ABS" menu appears on the matrix display. In the "MTC/ABS" menu, "MTC" and "ABS" can be switched off.
7 COMBINATION INSTRUMENT 7.9.11 "Load" 56 Condition • Model with EDS. 401833-01 7.9.12 • The vehicle is stationary. • Engine is running. – Press the UP or DOWN button until the "Load" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the UP or DOWN button to select a load status. Press the SET button to confirm the selection. In the "Load" menu, you can choose between four load states. "Damping" Condition • Model with EDS.
7 COMBINATION INSTRUMENT 7.9.13 "Drive Mod" 57 – 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. The SET button can be used to select engine and traction control settings that are coordinated with each other.
7 COMBINATION INSTRUMENT 7.9.
7 COMBINATION INSTRUMENT KTM start screen Menu buttons "Favorites" "Trip 1" "Trip 2" "General Info" "TPMS" (optional) "Set Favorites" "Settings" "Warning" (only active if there are messages) "Heating" (optional) "MTC/ABS" "Load" (model with EDS) "Damping" (model with EDS) "Drive Mod" 59
7 COMBINATION INSTRUMENT 7.9.15 "Language" 60 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 7.9.16 "Distance" Condition • The vehicle is stationary.
7 COMBINATION INSTRUMENT 7.9.17 "Temp" 61 Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Temp" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure. Select "°C" or "°F" for the temperature indicator. 402431-12 7.9.18 "Pressure" Condition • The vehicle is stationary.
7 COMBINATION INSTRUMENT 7.9.19 "Fuel Cons" 62 Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Fuel Cons" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure. Select one of the available consumption displays. 402431-14 7.9.20 "Clock/Date" Condition • The vehicle is stationary.
7 COMBINATION INSTRUMENT 7.9.21 "Shift Light" 63 Condition • The vehicle is stationary. L01433-10 7.9.22 – 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.
7 COMBINATION INSTRUMENT 7.9.23 "DRL" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "DRL" is highlighted in black on the matrix display. Pressing the SET button again switches the daytime running light on or off. Switch the daytime running light on or off. Info L01439-16 Note the legal regulations regarding the daytime running light.
8 ERGONOMICS 8.1 Adjusting the driver's seat 65 Preparatory work – Remove the passenger seat. ( p. 101) Alternative 1 – Attach the driver's seat to the fuel tank at the recesses seat down and forward at the same time. , and push the driver's Alternative 2 – Attach the driver's seat to the fuel tank at the recesses seat up and forward at the same time. , and push the driver's 401678-10 – Finally, check that the driver's seat is correctly mounted.
8 ERGONOMICS 8.2 Handlebar position 66 The holes on the handlebar support are placed at a distance of Hole distance from the center. 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 8.3 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage.
8 ERGONOMICS 67 Guideline Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™ Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure the cables and wiring are positioned correctly. – Position the handlebar clamps. Mount and evenly tighten screws . Guideline Screw, handlebar clamp Info Make sure the gap widths are even. M8 20 Nm (14.
8 ERGONOMICS 8.4 Adjusting the wind shield 68 – Pull the clamping lever in the direction of the arrow. The windshield is unlocked. S00344-10 – S00345-01 Move the wind shield in the required position.
8 ERGONOMICS 69 – Push the clamping lever in the direction of the arrow. The windshield is locked. S00344-11 8.5 Adjusting basic position of clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw . Info M00551-10 Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
8 ERGONOMICS 8.6 Adjusting the basic position of the hand brake lever 70 – Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel . Info Push the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding. S00243-10 8.7 Rider footrests The rider footrests can be mounted in one of two positions.
8 ERGONOMICS 8.8 Adjusting the footrests 71 Info The operations on the footrest brackets are the same for the left and right sides. – Remove screw . The foot brake lever swings up to the stop. M00643-10 – – with washer . Carefully remove the pin of the rider footrest. Remove cotter pin Info The spring is under high tension and can pop out when the pin is removed. – M00644-10 Take off the rider footrest with the spring.
8 ERGONOMICS 72 – Remove screws – Adjust the footrest bracket to the desired position. – Mount and tighten screws . M00645-10 602625-01 . Guideline Screw, front footrest bracket M00645-10 M8 25 Nm (18.
8 ERGONOMICS 73 – Mount the rider footrest with spring and pin . Pliers for footrest spring (58429083000) – Mount washer – Position the foot brake lever. – Mount and tighten screw and cotter pin . M00598-10 . Guideline Screw, ball joint of push rod on foot brake cylinder M6 10 Nm (7.4 lbf ft) M00643-10 8.9 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the driver's boot when in the basic position.
8 ERGONOMICS 74 – Sit on the vehicle in the riding position and determine distance edge of your boot and the shift lever. 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: – Adjust the basic position of the shift lever. ( p. 74) 400692-10 8.10 Adjusting the basic position of the shift lever – 402299-12 Remove screw between the upper with washers and take off shift lever .
8 ERGONOMICS 75 – Clean gear teeth – Mount the shift lever on the shift shaft in the required position and engage the gearing. 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 Locate and tighten screw Screw, shift lever 8.11 with washers. Guideline M6 18 Nm (13.
8 ERGONOMICS 76 – Mount and tighten screw . Guideline Screw, ball joint of push rod on foot brake cylinder – Attach spring . M6 10 Nm (7.
9 PREPARING FOR USE 9.1 Advice on first use 77 Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
9 PREPARING FOR USE 78 Warning Danger of accidents Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking. Info When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
9 PREPARING FOR USE 79 Info If the maximum engine speed is exceeded before the first service, the shift warning light flashes. 9.3 Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.
9 PREPARING FOR USE 80 Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload. – Adapt your speed according to your payload. Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.
10 RIDING INSTRUCTIONS 10.1 Checks and maintenance measures when preparing for use 81 Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. – Check the engine oil level. ( – Check the brake fluid level of the front brake. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( – Check the rear brake linings.
10 RIDING INSTRUCTIONS 10.2 Starting 82 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
10 RIDING INSTRUCTIONS – 83 Press the electric starter button . Info Do not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start. Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again.
10 RIDING INSTRUCTIONS 84 Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger. – The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles.
10 RIDING INSTRUCTIONS 85 Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of accidents Lack of roadworthiness.
10 RIDING INSTRUCTIONS 86 – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info You can see the positions of the 6 forward gears in the figure. The idle position is between the first and second gears. First gear is used for starting off or for steep inclines.
10 RIDING INSTRUCTIONS 87 Info Very important messages are stored in the "Warning" menu. – 10.5 If the icy road symbol appears in the combination instrument, the roads may be icy. Adjust your speed to the road conditions. Applying the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system. – Clean or dry a dirty or wet brake system by riding and braking gently.
10 RIDING INSTRUCTIONS 88 Warning Danger of accidents Greater stopping distance due to ABS. – Braking should be appropriate to the driving situation and the road conditions. Warning Danger of accidents Very forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents Vehicle rollover – – It is not always possible to prevent vehicle rollover in extreme riding situations (e. g.
10 – RIDING INSTRUCTIONS 89 On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over-rev the engine. In this way, you have to brake far less and the brakes do not overheat. 10.6 Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle unattended while the engine is running. Secure the vehicle against use by unauthorized persons.
10 RIDING INSTRUCTIONS 90 Note Material damage Damage and destruction of components from excessive load. – The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when it is resting on the center stand. The center stand or the frame may become damaged and the motorcycle may fall over. – Pull the motorcycle up onto the center stand at the grab handles. – Apply the brakes on the motorcycle.
10 RIDING INSTRUCTIONS 10.7 Transport 91 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. 401475-01 – Switch off the engine.
10 RIDING INSTRUCTIONS 10.8 Refueling 92 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard.
10 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( – Fill the fuel tank with fuel up to the lower edge Total fuel tank capacity, approx. – S00346-10 93 Close the filler cap. ( p. 34) 23 l (6.1 US gal) p. 36) of the filler neck. Super unleaded (ROZ 95/RON 95/PON 91) ( p.
11 SERVICE SCHEDULE 11.1 Additional information 94 Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately. 11.2 Required work Every two years Every year Every 30,000 km (18,600 mi) Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ○ Read out the trouble code memory using the KTM diagnostics tool.
11 SERVICE SCHEDULE 95 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 air filter. Clean the air filter box. ● ● Check the cables for damage and routing without sharp bends. (fuel tank removed) ● ● ● ● Clean the dust boots of the fork legs. Check the chain, rear sprocket and engine sprocket. ( Check the chain tension. ( p. 108) p.
11 SERVICE SCHEDULE 96 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) Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Check the CO adjustment with the KTM diagnostics tool. ○ ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.
11 SERVICE SCHEDULE 97 Every four years Every two years Every year Every 15,000 km (9,300 mi) After 1,000 km (620 mi) Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing. ○ Check the antifreeze. Check/correct the fluid level of the hydraulic clutch. ( p. 111) ● ● ● ● ● ● ● ● ● ● ● ● ● ● Change the hydraulic clutch fluid. Check the screws and nuts for tightness. Change the coolant.
12 SUSPENSION SETTING 12.1 "Damping" (Option: With EDS) 98 Possible states • SPORT – Firm tuning of the spring elements with very direct feedback from the chassis • STREET – Normal tuning of the spring elements with direct feedback from the chassis • COMFORT – Soft tuning of the spring elements with good feedback from the chassis Different tunings for the damping of the spring elements can be selected in the "Damping" menu. You can choose from "SPORT", "STREET", and "COMFORT". 401831-01 12.
12 SUSPENSION SETTING 12.3 Fork/shock absorber (Option: With EDS) The EDS(Electronic Damping System) can be used to tune the suspension individually without the use of tools. Always adapt the suspension to your riding style and the payload. In the "Load" menu, the suspension can be set to the payload. In the "Damping" menu, the damping behavior of the suspension can be set.
13 SERVICE WORK ON THE CHASSIS 13.1 Raising the vehicle with the center stand (Option: Center stand) 100 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Material damage Damage and destruction of components from excessive load. – The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when it is resting on the center stand.
13 SERVICE WORK ON THE CHASSIS 101 – Make sure that the steering is unlocked. – Move the vehicle forward with both hands on the handlebar. – While the vehicle tips off of the center stand, activate the front brake to stop the vehicle from rolling away. – Check that the center stand – Insert the ignition key in seat lock – Raise the front of the passenger seat, pull it toward the tank, and remove it upward. – Remove the ignition key. is folded all the way up. 402033-10 13.
13 SERVICE WORK ON THE CHASSIS 13.4 Mounting the passenger seat 102 – Attach the hooks on the passenger seat to the brackets on the subframe, and lower at the front while pushing toward the rear. – Insert locking pin into the lock housing and push down the front of the passenger seat until the locking pin engages with a click. – Check that the passenger seat is correctly mounted. 401680-10 13.5 Removing the driver's seat Preparatory work – Remove the passenger seat. ( p.
13 SERVICE WORK ON THE CHASSIS 13.6 Mounting the driver's seat 103 Main work – Attach the recesses on the driver's seat to the fuel tank at the desired seat position or , and push the driver's seat forward while lowering it at the rear. – Finally, check that the driver's seat is correctly mounted. 401704-10 Finishing work – Mount the passenger seat. ( 13.7 p. 102) Checking for chain dirt – Check the chain for coarse dirt accumulation.
13 SERVICE WORK ON THE CHASSIS 13.8 Cleaning the chain 104 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage.
13 SERVICE WORK ON THE CHASSIS 105 Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( – p. 217) After drying, apply chain spray. Chain lube for road use ( p. 217) 400725-01 Finishing work (Option: Center stand) – Remove the vehicle from the center stand. ( 13.9 p. 100) Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension.
13 SERVICE WORK ON THE CHASSIS Main work – Shift the transmission to idle – 106 . In the area in front of the chain guide, push the chain up and determine chain tension . Info The upper part of the chain must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. 401664-10 Chain tension » 40… 45 mm (1.57… 1.77 in) If the chain tension does not meet the specification: – Adjust the chain tension. ( p.
13 SERVICE WORK ON THE CHASSIS 107 Preparatory work (Option: Center stand) – Raise the vehicle with the center stand. ( – Check the chain tension. ( p. 100) p. 105) Main work – Loosen nut – . Loosen nuts . – Adjust the chain tension by turning the adjusting screws on the left and right. Guideline Chain tension 40… 45 mm (1.57… 1.
13 SERVICE WORK ON THE CHASSIS 108 Info Chain adjusters can be turned through 180°. Finishing work (Option: Center stand) – Remove the vehicle from the center stand. ( 13.11 p. 100) Checking the chain, rear sprocket and engine sprocket Preparatory work (Option: Center stand) – Raise the vehicle with the center stand. ( p. 100) Main work – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the power set.
13 SERVICE WORK ON THE CHASSIS 109 – Shift the transmission to idle – Pull the lower chain section with specified weight . . Guideline Weight, chain wear measurement – Measure distance 15 kg (33 lb.) of 18 chain rollers on the upper part of the chain. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance chain section » 0 If distance – at the longest 272 mm (10.
13 SERVICE WORK ON THE CHASSIS – 110 Check the chain sliding guard for wear at the cutout. Info When the chain sliding guard is new, the rivets edge of the recess. are half visible at the bottom » When the rivets of the chain are no longer visible at the bottom edge of the recess of the chain sliding guard: – M00556-10 – Change the chain sliding guard. Check the chain sliding guard for tightness. » If the chain sliding guard is loose: – Tighten the screws on the chain sliding guard.
13 SERVICE WORK ON THE CHASSIS 13.12 Checking/correcting the fluid level of the hydraulic clutch 111 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Environmental hazard Hazardous substances cause environmental damage.
13 SERVICE WORK ON THE CHASSIS 112 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – . Remove cover with membrane . – Check the fluid level. Fluid level below container rim » If the fluid level does not meet specifications: – Correct the fluid level of the hydraulic clutch. S00270-10 Brake fluid DOT 4 / DOT 5.1 ( – 4 mm (0.16 in) p. 214) Position the cover with the membrane. Mount and tighten the screws.
13 SERVICE WORK ON THE CHASSIS 113 Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. – Move the handlebar to the straight-ahead position. Move the fork legs back and forth in the direction of travel. Play should not be detectable on the steering head bearing. » 400738-11 If there is no detectable play: – – Adjust the steering head bearing play. Move the handlebar to and fro over the entire steering range.
13 SERVICE WORK ON THE CHASSIS 13.14 Removing the bottom triple clamp cover – Remove screws – Lower the triple clamp cover – Disconnect plugs 114 . slightly. M00557-10 M00558-10 – of the horn. Detach temperature sensor . – Remove the triple clamp cover.
13 SERVICE WORK ON THE CHASSIS 13.15 Installing the bottom triple clamp cover – 115 – of the horn. Attach temperature sensor . – Position the triple clamp cover – Mount and tighten screws Plug in connectors M00558-11 . . Guideline Remaining chassis screws M00557-11 M6 10 Nm (7.
13 SERVICE WORK ON THE CHASSIS 13.16 Removing the front side cover – Remove screw – Remove screws . G00576-10 M00560-10 – . Remove side cover . – Repeat the operation on the opposite side.
13 SERVICE WORK ON THE CHASSIS 13.17 Installing the front side cover – Position the side cover in the – Attach catch 117 area under the tank cover. M00561-10 G00679-10 of the side cover to bracket and position on the fuel tank.
13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 118 . Guideline Screw, cover part M5 3.5 Nm (2.58 lbf ft) M5 3.5 Nm (2.58 lbf ft) G00576-11 – Mount and tighten screws . Guideline Screw, cover part – Repeat the operation on the opposite side. M00560-11 13.18 Removing the mask spoiler Preparatory work – Remove the passenger seat. ( p. 101) – Remove the driver's seat. ( – Remove the front side cover. ( – Remove the tank cover. ( p. 102) p. 116) p.
13 SERVICE WORK ON THE CHASSIS Main work – Remove screw . – Remove screw . – Loosen holding lug G00581-10 K00340-10 602638-10 from the inside cover.
13 SERVICE WORK ON THE CHASSIS 120 – Remove the mask spoiler laterally from the supports. – 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. G00584-10 . G00585-10 G00586-10 .
13 SERVICE WORK ON THE CHASSIS 13.19 Installing the mask spoiler Main work – Connect plug-in connector 121 . G00586-11 – Position the mask spoiler in bracket . Info Ensure that the turn signal cable is placed correctly.
13 SERVICE WORK ON THE CHASSIS 122 – Press the mask spoiler laterally into the supports. – Position holding lug – Mount and tighten screw G00584-11 in the drill hole. G00583-10 . Guideline Screw, mask spoiler K00340-11 M5x17 3.5 Nm (2.
13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 123 . Guideline Screw, mask spoiler – M5x17 Repeat the operation on the opposite side. G00581-11 Finishing work – Install the tank cover. ( 13.20 p. 126) – Install the front side cover. ( – Mount the driver's seat. ( – Mount the passenger seat. ( – Open holder p. 117) p. 103) p. 102) Removing the front fender – and detach the brake lines and cable. Remove screws . – Remove the fender in a forward direction.
13 SERVICE WORK ON THE CHASSIS 13.21 Installing the front fender – 124 Position the fender. Info Pay attention to the routing of the brake lines and the cable. – Mount and tighten screws . Guideline Screw, fender S00356-11 13.22 – M5x12 Insert the brake lines and cable in brackets Removing the tank cover Preparatory work – Remove the passenger seat. ( Remove the driver's seat. ( – Remove the front side cover. ( Main work – Remove screw – 202565-10 p. 101) – . Remove screw . p.
13 SERVICE WORK ON THE CHASSIS – – . Remove screw . – Remove screw – Raise the tank cover at the rear and remove it in a forward direction. Remove screw 202566-10 .
13 SERVICE WORK ON THE CHASSIS 13.23 Installing the tank cover 126 Main work – Position the tank cover. Info Note the sealing lip. – Mount and tighten screw . Guideline Screw, cover part M5 3.5 Nm (2.58 lbf ft) M6 6 Nm (4.4 lbf ft) M5 3.5 Nm (2.58 lbf ft) G00579-11 – Mount and tighten screw . Guideline Screw, cover part – Mount and tighten screw .
13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 127 . Guideline Screw, cover part – Mount and tighten screw M6 6 Nm (4.4 lbf ft) M5 3.5 Nm (2.58 lbf ft) . Guideline Screw, cover part 202566-11 Finishing work – Install the front side cover. ( 13.24 – Mount the driver's seat. ( – Mount the passenger seat. ( – Remove screws p. 117) p. 103) p. 102) Removing the wind shield K00341-10 and wind shield .
13 SERVICE WORK ON THE CHASSIS 13.25 Installing the wind shield – Position wind shield – Mount and tighten screws 128 . . Guideline Screw, wind shield K00341-11 13.26 Removing the engine guard – S00331-10 Remove screws and engine guard . M5 3.5 Nm (2.
13 SERVICE WORK ON THE CHASSIS 13.27 Installing the engine guard – Position engine guard 129 . Mount and tighten screws . Guideline Screw, engine guard S00331-11 M6 10 Nm (7.
14 BRAKE SYSTEM 14.1 ABS/antilock brake system 130 The ABS unit , which consists of a hydraulic unit, brake electronics control unit, and return pump, is installed under the seat. A wheel speed sensor is located at the front and rear wheels. 3 0 2 0 Warning Danger of accidents Functional limitations of the ABS – The rear wheel may only be spun with the front brake applied (burn out) if the ABS is switched off.
14 BRAKE SYSTEM 131 Warning Danger of accidents Vehicle rollover – It is not always possible to prevent vehicle rollover in extreme riding situations (e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your driving ability. ABS has two operating modes: the "Road" and "Offroad" ABS modes.
14 BRAKE SYSTEM 132 Info After the ignition is switched back on, ABS is enabled again. MSC (optional) The MSC "Motorcycle Stability Control" is an advancement of the ABS described above. By means of the 5D sensor, ABS control is now dependent on the inclination and pitch angle. ABS control that is dependent on the inclination and pitch angle improves the riding stability and braking effect in all riding situations. The MSC also reduces the righting moment during strong braking in curves.
14 BRAKE SYSTEM 133 – Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness . Info Wear will reduce the thickness of the brake disc at the contact surface the brake linings. of Brake discs - wear limit 400618-10 » Front 4 mm (0.16 in) Rear 4.5 mm (0.177 in) If the brake disc thickness is less than the specified value. – – Check the front and rear brake discs for damage, cracking, and deformation.
14 BRAKE SYSTEM 134 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in the brake fluid reservoir » . If the brake fluid has dropped below marking MIN: – Add front brake fluid. ( p. 134) S00269-10 14.4 Adding front brake fluid Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
14 BRAKE SYSTEM 135 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
14 BRAKE SYSTEM 14.5 Checking the front brake linings 136 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.
14 BRAKE SYSTEM 137 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work (Option: Center stand) – Raise the vehicle with the center stand. ( p. 100) Main work – Check the brake fluid level in the brake fluid reservoir » If the fluid level reaches the MIN marking – Add rear brake fluid. ( . : p.
14 BRAKE SYSTEM 138 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid.
14 BRAKE SYSTEM 139 Main work – Remove screw cap – with membrane . . Add brake fluid to the MAX mark Brake fluid DOT 4 / DOT 5.1 ( – Mount and tighten screw cap p. 214) with membrane . Info S00359-10 14.8 Clean up overflowed or spilt brake fluid immediately with water. Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.
14 BRAKE SYSTEM 140 – Check the brake linings for minimum thickness Minimum thickness » Change the rear brake linings. Check the brake linings for damage and cracking. » If there is wear or tearing: – S00958-10 ≥ 1 mm (≥ 0.04 in) If the minimum thickness is less than specified: – – . Change the rear brake linings.
15 WHEELS, TIRES 15.1 Removing the front wheel 141 Preparatory work (Option: Center stand) – Raise the vehicle with the center stand. ( p. 100) Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. – Remove screw – Remove screws – Press back the brake linings with a slight lateral tilting of the brake calipers on the brake disc. – Pull the brake calipers carefully back from the brake discs and hang them to one side loosely.
15 WHEELS, TIRES 142 – – – – by several rotations. Loosen screws . Press on screw to push the wheel spindle out of the axle clamp. Remove screw . Loosen screw Warning Danger of accidents Reduced braking efficiency due to damaged brake discs. – S00364-10 – Always lay down the wheel in such a way that the brake discs are not damaged. Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed.
15 WHEELS, TIRES 15.2 Installing the front wheel 143 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Change the wheel bearing. Clean and grease shaft seal rings Long-life grease ( and contact surface of the spacers. p.
15 WHEELS, TIRES 144 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Clean and grease screw Long-life grease ( S00365-10 and wheel spindle . p. 217) – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw . Guideline Screw, front wheel spindle M25x1.5 45 Nm (33.
15 WHEELS, TIRES 145 – Position the wheel speed sensor – Mount and tighten screw in the drill hole. . Guideline Remaining chassis screws M6 (Option: Center stand) – Remove the vehicle from the center stand. ( 10 Nm (7.4 lbf ft) p. 100) S00362-11 – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws . Guideline Screw, fork stub M8 S00364-11 15.
15 WHEELS, TIRES 146 Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. M00612-01 – Remove screw – Remove nut and pull wheel speed sensor out of the hole. S00277-10 S00276-10 . Remove chain adjuster .
15 WHEELS, TIRES 147 – Pull out wheel spindle – Push the rear wheel forward as far as possible. Take the chain off of the rear sprocket and place it on chain sprocket guard . only far enough to allow the rear wheel to be pushed forward. Warning Danger of accidents Reduced braking effect caused by damaged brake discs. – M00613-10 – Always lay the wheel down in such a way that the brake discs are not damaged. Holding the rear wheel, withdraw the wheel spindle.
15 WHEELS, TIRES 148 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Change the wheel bearing. Clean and grease shaft seal ring Long-life grease ( – M00615-10 p. 217) Clean and grease the thread of the wheel spindle and nut. Long-life grease ( M00614-10 and contact surface of the spacer. p. 217) – Install the rubber dampers and rear sprocket carrier on the rear wheel.
15 WHEELS, TIRES 149 – Push the wheel spindle in all the way and mount chain adjuster and nut . Info Mount chain adjusters – and in the same position. Make sure that the chain adjusters are fitted correctly on the adjusting screws. Guideline M00631-10 In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks . – Tighten nut . Guideline Nut, rear wheel spindle M25x1.
15 WHEELS, TIRES 15.5 Checking the rear hub rubber dampers 150 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. The rubber dampers wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. Preparatory work (Option: Center stand) – Raise the vehicle with the center stand. ( – Remove the rear wheel. Main work – Check the rubber dampers » p. 100) p.
15 WHEELS, TIRES 151 – Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub. – Check the rear sprocket play . Info Measure the play on the outside of the rear sprocket. Play in rubber dampers, rear wheel M00617-10 » If clearance – larger than the specified value: Change all rubber dampers in the rear hub. Finishing work – Install the rear wheel. 15.6 ≤ 5 mm (≤ 0.2 in) ( p.
15 WHEELS, TIRES 152 Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in. Info The type, condition and air pressure of the tires all have an impact on the braking and riding response of the vehicle.
15 WHEELS, TIRES 153 Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. » If a tire is more than five years old: – 15.7 Change the tires.
15 WHEELS, TIRES 15.8 Checking spoke tension 154 Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can easily cause lateral or radial runout on the wheel. More spokes loosen in a short period. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle.
16 ELECTRICAL SYSTEM 16.1 daytime running light 155 The daytime running light/parking light is integrated in the main headlight. The daytime running light (DRL) can be switched on when visibility conditions are good. Activate the daytime running light in the combination instrument. Control is provided by the brightness sensor in the combination instrument. When visibility conditions are good, the low beam is switched off and the daytime running light is switched on.
16 ELECTRICAL SYSTEM 156 Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( – Remove the driver's seat. ( Main work – Pull locking mechanism p. 101) p. 102) in the direction of the arrow. – Fold open cover – Disconnect negative cable . M00572-10 – – M00573-10 from the battery. Disconnect positive cable from the battery. Take the battery and battery case out of the battery compartment.
16 ELECTRICAL SYSTEM 16.3 Installing the battery 157 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms. – In the event of skin contact, rinse with large amounts of water.
16 ELECTRICAL SYSTEM 158 Guideline Screw, battery terminal – Close the cover M6 4.5 Nm (3.32 lbf ft) and push down slightly. The cover engages with an audible click. M00572-11 Finishing work – Mount the driver's seat. ( 16.4 – Mount the passenger seat. ( – Set the time and date. p. 103) p. 102) Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children.
16 ELECTRICAL SYSTEM 159 Warning Environmental hazard The battery contains elements that are harmful to the environment. – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc.
16 ELECTRICAL SYSTEM 160 Main work – Pull locking mechanism in the direction of the arrow. – Fold open cover – Disconnect negative cable tronics. – Connect the battery charger to the battery. Switch on the battery charger. . M00572-10 of the battery to avoid damage to the motorcycle's elec- M00562-10 Battery charger (58429074000) Info M00775-01 You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator.
16 ELECTRICAL SYSTEM – 161 Switch off the battery charger after charging and disconnect from the battery. Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly when the motorcycle is not in use – Connect both negative cables 3 months with the battery. Guideline Screw, battery terminal M6 M00562-10 – Close cover and push down slightly. The cover engages with an audible click.
16 ELECTRICAL SYSTEM – 16.5 162 Set the time and date. Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( – Remove the driver's seat. ( Main work – Remove screws – K00334-10 . Raise rear fairing slightly. p. 101) p.
16 ELECTRICAL SYSTEM 163 – Remove protection caps – Remove the faulty main fuse . M00564-10 . Info A defective fuse is indicated by a burned-out fuse wire . A reserve fuse is located in the starter relay. The main fuse protects all power consumers of the vehicle. – M00565-10 Install a new main fuse. Fuse (58011109130) ( p. 208) – Check that the electrical equipment is functioning properly. – Mount protection covers.
16 ELECTRICAL SYSTEM 164 – Position rear fairing – Mount and tighten screws . . Guideline Screw, cover part M5 K00334-10 Finishing work – Mount the driver's seat. ( 16.6 – Mount the passenger seat. ( – Set the time and date. p. 103) p. 102) Changing the fuses in the fuse box Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses.
16 ELECTRICAL SYSTEM 165 Main work – Open fuse box cover . M00566-10 (Option: With EDS) – Check the fuses. Info A defective fuse is indicated by a burned-out fuse wire – . Remove the defective fuse.
16 ELECTRICAL SYSTEM 166 Fuse (58011109115) ( p. 208) Fuse (58011109125) ( p. 208) Fuse (58011109140) ( p. 208) Tip Insert a spare fuse so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the passenger seat. ( 16.7 p. 102) Removing the headlight mask with the headlight Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat.
16 ELECTRICAL SYSTEM 167 Main work – Remove screws . – Remove the headlight mask forward. – Disconnect plug-in connector – Place the headlight mask onto a soft cloth so that the headlight is not damaged. S00368-10 602645-10 .
16 ELECTRICAL SYSTEM 16.8 Refitting the headlight mask with the headlight 168 Main work – Connect plug-in connector of the headlight. – Check that the lighting is functioning properly. – Position the headlight mask. – Mount and tighten screws 602645-11 . Guideline Remaining chassis screws M6 S00368-11 Finishing work – Install the wind shield. ( p. 128) – Install the mask spoiler. ( – Install the tank cover. ( – Install the front side cover. ( – Mount the driver's seat.
16 ELECTRICAL SYSTEM – 16.9 169 Check the headlight setting. ( p. 173) Changing the low beam bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( – Remove the driver's seat. ( – Remove the front side cover. ( – Remove the tank cover.
16 ELECTRICAL SYSTEM – 170 Plug connector into the new headlight bulb. Low beam (H11/socket PGJ19-2) ( – Position headlight bulb p. 208) into the bulb socket and turn it all the way clockwise. The headlight bulb is locked into the bulb socket. S00298-10 Finishing work – Refit the headlight mask with the headlight. ( 16.10 – Install the wind shield. ( p. 128) – Install the mask spoiler. ( – Install the tank cover. ( – Install the front side cover. ( – Mount the driver's seat.
16 ELECTRICAL SYSTEM 171 Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( – Remove the driver's seat. ( – Remove the front side cover. ( – Remove the tank cover. ( – Remove the mask spoiler. ( – Remove the wind shield. ( p. 127) – Remove the headlight mask with the headlight. ( Main work – Push headlight bulb wise, and pull it out. – Unplug connector – Plug connector p. 101) p. 102) p. 116) p. 124) p. 118) p.
16 ELECTRICAL SYSTEM 172 Finishing work – Refit the headlight mask with the headlight. ( 16.11 – Install the wind shield. ( p. 128) – Install the mask spoiler. ( – Install the tank cover. ( – Install the front side cover. ( – Mount the driver's seat. ( – Mount the passenger seat. ( – Check the headlight setting. ( p. 168) p. 121) p. 126) p. 117) p. 103) p. 102) p. 173) Changing the turn signal bulb (1190 Adventure CN) Note Damage to reflector Reduced brightness.
16 ELECTRICAL SYSTEM 173 – Check the turn signal to make sure it is functioning properly. – Position the diffuser. Info Hook in projection 16.12 at recess . – Insert the screw and first turn it counterclockwise until it engages in the thread. Tighten the screw slightly. – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the height of the center of the low beam headlight.
16 ELECTRICAL SYSTEM 16.13 Adjusting the headlight range 174 Preparatory work – Check the headlight setting. ( – p. 173) Remove the bottom triple clamp cover. ( Main work – Turn adjusting screw p. 114) to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range. If you have a payload, you may have to correct the headlight range. M00569-10 – Set the headlight to marking .
16 ELECTRICAL SYSTEM 16.14 Activating/deactivating the ignition key 175 Info The orange programming key must only be used for activating and deactivating! If a black ignition key is lost or needs to be replaced, the individual black ignition keys need to be enabled or disabled using the orange programming key. This prevents the vehicle from being operated with the lost black ignition key. You can activate or deactivate up to four black ignition keys.
16 ELECTRICAL SYSTEM 176 – Switch off the ignition by turning the black ignition key to the position OFF – Remove the black ignition key. – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position . . The immobilizer indicator lamp flashes according to the number of functional black ignition keys including the orange programming key. In this case, it flashes twice.
16 ELECTRICAL SYSTEM 177 – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position Immobilizer indicator lamp . lights up. – Switch off the ignition by turning the orange programming key to the OFF position – Switch on the ignition by turning the orange programming key to the ON position . .
16 ELECTRICAL SYSTEM 178 – If the last black ignition key was activated, insert the orange programming key into the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position . The immobilizer indicator lamp flashes according to the number of functional black ignition keys including the orange programming key. – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. .
16 ELECTRICAL SYSTEM 179 Info After the fourth black ignition key has been activated, programming is finished.
17 COOLING SYSTEM 17.1 Checking the coolant level in the compensating tank 180 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water. Warning Danger of poisoning Coolant is poisonous and a health hazard.
17 COOLING SYSTEM 181 – 17.2 Correct the coolant level in the compensating tank. ( p. 181) Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
17 COOLING SYSTEM 182 Main work – Remove cover of the compensating tank. K00339-10 – Add coolant until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX. Coolant ( – p. 214) Mount the cover of the compensating tank. 602648-01 Finishing work – Install the front side cover. ( p.
18 TUNING THE ENGINE 18.
18 TUNING THE ENGINE 184 Info When motorcycle traction control is active, the TC lamp flashes. When motorcycle traction control is switched off, the TC lamp lights up.
19 SERVICE WORK ON THE ENGINE 19.1 Checking the engine oil level 185 Info Oil consumption depends on the riding style and the operating conditions. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level in the engine oil level viewer. Info After switching off the engine, wait one minute before checking the level. The engine oil level should be in the upper part of the range level viewer.
19 SERVICE WORK ON THE ENGINE 19.2 Changing the engine oil and oil filter, cleaning the oil screens 186 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc.
19 SERVICE WORK ON THE ENGINE – Remove screws – Pull oil filter 187 . Remove the oil filter cover with the O-ring. S00334-10 out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. – Insert oil filter – Lubricate the O-ring of the oil filter cover. Mount the oil filter cover S00335-10 S00336-10 . .
19 SERVICE WORK ON THE ENGINE – Mount and tighten screws 188 . Guideline Remaining engine screws M5 6 Nm (4.4 lbf ft) S00334-11 – Thoroughly clean magnets – Mount and tighten the oil drain plugs and oil screens of the oil drain plugs. 100773-12 with the magnets, O-rings, and oil screens. Guideline Oil drain plug S00333-10 M20x1.5 20 Nm (14.
19 SERVICE WORK ON THE ENGINE – 189 Add the oil quantity in two separate operations. Engine oil – M00958-10 3.60 l (3.8 qt.) Remove screw plug Mount screw plug Engine oil (SAE 10W/50) ( p. 214) Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 215) Outside temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 214) Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 215) and fill in engine oil. Engine oil (1st quantity) approx.
19 SERVICE WORK ON THE ENGINE 190 – Remove the screw plug and add the remaining engine oil to the upper marking the engine oil level viewer. – Mount the screw plug. on Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – S00367-10 – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
19 SERVICE WORK ON THE ENGINE Main work – Remove screw plug 191 . M00958-11 – Add engine oil to the upper marking on the engine oil level viewer. Condition Outside temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 214) Condition Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( S00367-10 p. 215) Info In order to achieve optimal engine performance, it is not advisable to mix different engine oils. KTM recommends changing the engine oil. – Mount the screw plug.
19 SERVICE WORK ON THE ENGINE 192 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and check that it is oil-tight. Finishing work – Check the engine oil level. ( p.
20 CLEANING, CARE 20.1 Cleaning motorcycle 193 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.
20 CLEANING, CARE 194 – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the closure of the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system. – – Clean or dry a dirty or wet brake system by riding and braking gently. After cleaning, ride the vehicle a short distance until the engine warms up.
20 CLEANING, CARE 195 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 218) – Oil the ignition/steering lock, tank lock, and seat lock. Universal oil spray ( 20.2 p. 218) Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding.
20 CLEANING, CARE 196 – Clean the chain. ( p.
21 STORAGE 21.1 Storage 197 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.
21 STORAGE 198 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 21.2 Preparing for use after storage (Option: Center stand) – Remove the vehicle from the center stand. ( – Install the battery. ( p. 100) p.
22 TROUBLESHOOTING 199 Faults Possible cause Action Combination instrument shows nothing on the display Fuse 1 blown – Change the fuses in the fuse box. ( Main fuse burned out – Change the main fuse. ( The battery is discharged – Recharge the battery. p. 164) p. 162) ( p. 158) – Check the quiescent current. Ignition/steering lock is faulty – Check the ignition/steering lock. Emergency OFF switch is off – Press the emergency OFF switch to the position ON .
22 TROUBLESHOOTING 200 Faults Possible cause Action Engine turns but does not start Fault in fuel injection system – Read out the fault memory using the KTM diagnostics tool. Fuel quality is insufficient – Add suitable fuel. Lack of fuel – Refuel. ( Fault in fuel injection system – Read out the fault memory using the KTM diagnostics tool. The engine warning lamp lights up/flashes Fault in fuel injection system – Read out the fault memory using the KTM diagnostics tool.
23 TECHNICAL DATA 23.1 Engine 201 Design 2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled Displacement 1,195 cm³ (72.92 cu in) Stroke 69 mm (2.72 in) Bore 105 mm (4.13 in) Compression ratio 12.5:1 Idle speed 1,300… 1,500 rpm Control DOHC, 4 valves per cylinder, chain-driven Valve - valve 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 202 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug Inside spark plug NGK LKAR9BI9 Outside spark plug NGK LMAR7A-9 Electrode gap, spark plug 0.9 mm (0.
23 TECHNICAL DATA Screw, bearing shells retaining bracket 203 M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, engine oil level viewer M5 4 Nm (3 lbf ft) – Screw, gear sensor M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, pulse generator M5 6 Nm (4.4 lbf ft) Loctite® 243™ Bleeder screw, water pump cover M6 10 Nm (7.4 lbf ft) – Freewheel ring bolt M6 – 10.9 15 Nm (11.1 lbf ft) Loctite® 648™ Nut, cylinder head M6 9 Nm (6.6 lbf ft) – Plug, vacuum connection M6 5 Nm (3.
23 TECHNICAL DATA 204 Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™ Stud, chain shaft M6 8 Nm (5.9 lbf ft) – 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 (13.3 lbf ft) – Screw, camshaft bearing support M8 – 10.9 Step 1 8.5 Nm (6.27 lbf ft) Step 2 14.5 Nm (10.
23 TECHNICAL DATA Screw, timing chain tensioner release 205 M10x1 10 Nm (7.4 lbf ft) – Spark plug M10x1 11 Nm (8.1 lbf ft) – Cylinder head screw M11x1.5 Tightening sequence: Using a crisscross pattern Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° Step 4 90° Lubricated with engine oil Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) – Rotor screw M12x1.5 90 Nm (66.4 lbf ft) – Spark plug M12x1.5 18 Nm (13.3 lbf ft) – Nut of engine sprocket M20x1.
23 TECHNICAL DATA Engine oil 23.3.2 3.60 l (3.8 qt.) Outside temperature: < 0 °C (< 32 °F) 2.40 l (2.54 qt.) Coolant ( Total fuel tank capacity, approx. 3.5 l (3.7 qt.) 23 l (6.1 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 216) Chassis Frame 23.4.1 p. 214) Fuel Fuel reserve, approx. 23.4 Engine oil (SAE 5W/40) ( p. 215) Coolant Coolant 23.3.
23 TECHNICAL DATA Rear 207 Single disc brake with dual-piston brake caliper, floating brake disc Brake discs - diameter Front 320 mm (12.6 in) Rear 267 mm (10.51 in) Brake discs - wear limit Front 4 mm (0.16 in) Rear 4.5 mm (0.177 in) Tire air pressure, solo/with passenger/full payload Front: with cold tires 2.4 bar (35 psi) Rear: with cold tires 2.9 bar (42 psi) Secondary drive ratio 17:42 Chain 5/8 x 5/16” (525) X‑ring Steering head angle 64° Wheelbase 1,560±15 mm (61.42±0.
23 TECHNICAL DATA 23.5 Electrical system 23.5.1 Option: With EDS 208 Battery YTZ14S Battery voltage: 12 V Nominal capacity: 11.
23 TECHNICAL DATA 23.6 Tires 209 Front tires Rear tires 120/70 ZR 19 M/C 60W TL Continental ContiTrailATTACK 2 K 170/60 ZR 17 M/C 72W TL Continental ContiTrailATTACK 2 K Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork 23.7.1 Option: With EDS Fork part number 14.18.9M.24 Fork WP Performance Systems 4860 MXTA SPLIT EDS Spring length with preload spacer(s) 393 mm (15.47 in) Spring rate Medium (standard) 6.0 N/mm (34.
23 TECHNICAL DATA 210 Spring rate Medium (standard) 160 N/mm (914 lb/in) Spring length 205 mm (8.07 in) Static sag 25 mm (0.98 in) Riding sag 55 mm (2.17 in) Fitted length 403 mm (15.87 in) Shock absorber fluid ( 23.9 p. 216) SAE 2.5 Chassis tightening torques Nut, tire pressure sensor 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) – Remaining screws, chassis M5 5 Nm (3.
23 TECHNICAL DATA 211 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 unit fixation M6 8 Nm (5.9 lbf ft) – Remaining chassis nuts M6 10 Nm (7.4 lbf ft) – Remaining chassis screws M6 10 Nm (7.4 lbf ft) – Screw, angle sensor M6 6 Nm (4.4 lbf ft) – Screw, ball joint of push rod on foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, battery terminal M6 4.5 Nm (3.
23 TECHNICAL DATA 212 Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™ Screw, retaining bracket, angle sensor M6 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, voltage regulator M6 6 Nm (4.4 lbf ft) – Screw, wheel speed sensor, front M6 10 Nm (7.4 lbf ft) – Screw, wheel speed sensor, rear M6 10 Nm (7.4 lbf ft) – Remaining chassis nuts M8 25 Nm (18.4 lbf ft) – Remaining chassis screws M8 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp M8 12 Nm (8.
23 TECHNICAL DATA 213 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) – Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) – Screw, bottom shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased Screw, top shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased Nut, socket M18x1 4 Nm (3 lbf ft) – Nut, swingarm pivot M19x1.5 130 Nm (95.
24 SUBSTANCES 214 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 – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Guideline – Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures).
24 SUBSTANCES 215 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 Engine oil (SAE 5W/40) Standard/classification – JASO T903 MA ( p. 219) – SAE ( p.
24 SUBSTANCES 216 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 219) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
25 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex® – Chainlube Road Fuel additive Recommended supplier Motorex® – Fuel Stabilizer Long-life grease Recommended supplier Motorex® – Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex® – Moto Clean 217
25 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex® – Moto Polish & Shine 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 Universal oil spray Recommended supplier Motorex® – Joker 440 Synthetic 218
26 STANDARDS 219 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
27 INDEX OF SPECIAL TERMS 220 ABS ABS 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 MTC Motorcycle Traction C
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.
29 LISY OF SYMBOLS 29.1 Red symbols 222 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 – Engine oil pressure is too low. 29.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.
29 LISY OF SYMBOLS 223 The left turn signal lamp flashes green simultaneously with the turn signal – The left turn signal is switched on. The idle indicator lamp lights up green – The transmission is shifted to idle. The right turn signal lamp flashes green simultaneously with the turn signal – The right turn signal is switched on.
INDEX 224 INDEX C A ABS . . . . . . . . . . . . Accessories . . . . . . . Antilock brake system Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 . 15 130 . 15 B Battery installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 recharging . . . . . . .
INDEX "Favorites" . . . . . . . . . . . . . . "Fuel Cons" . . . . . . . . . . . . . . "General Info" . . . . . . . . . . . . "Heat Grips" . . . . . . . . . . . . . "Heating" menu . . . . . . . . . . . indicator lamps . . . . . . . . . . "Language" . . . . . . . . . . . . . . "Load" . . . . . . . . . . . . . . . . . "Load" menu . . . . . . . . . . . . . matrix display . . . . . . . . . . . Menu overview . . . . . . . . . . . message on the matrix display "MTC" . . . . . . . . . . . . . . . . . overview . . .
INDEX 226 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H F Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 70 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Filler cap closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 227 Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L P Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Passenger footrest . . . . . . . . . . . . . . . . . . . . . .
INDEX 228 S Safe operation . Seat lock . . . . Service . . . . . . Service schedule .... .... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . 39 . . . 16 94-97 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 basic position, adjusting . . . . . . . . . . . .
INDEX 229 Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Triple clamp cover, bottom installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Troubleshooting . . . . . . . . . . .
*3213387en* 3213387en 09/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria http://www.ktm.
