OWNER'S MANUAL 2012 990 Supermoto T USA 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 accordingly. DEAR KTM CUSTOMER We wish you a lot of enjoyment in riding this vehicle. Please enter the serial numbers of your vehicle below. Chassis number/type label ( Engine number ( Key number ( p. 26) Dealer's stamp p. 28) p.
DEAR KTM CUSTOMER © 2012 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
TABLE OF CONTENTS TABLE OF CONTENTS MEANS OF REPRESENTATION ............................................... 7 IMPORTANT INFORMATION ................................................... 8 Overview of labels............................................................. 12 VIEW OF VEHICLE................................................................ 22 View of vehicle, front left side (example)............................. 22 View of vehicle, rear right side (example) ............................
TABLE OF CONTENTS RIDING INSTRUCTIONS ....................................................... Checks and maintenance measures when preparing for use ................................................................................. Starting ........................................................................... Starting off ...................................................................... Shifting, riding ................................................................. Braking .....................
TABLE OF CONTENTS Installing the front wheel ............................................ Removing the rear wheel ............................................ Installing the rear wheel ............................................. Checking rear hub shock absorbers ............................. Checking the tire condition.............................................. Checking the tire air pressure .......................................... ELECTRICAL SYSTEM ...................................................
TABLE OF CONTENTS TECHNICAL DATA - CHASSIS ............................................. Lighting equipment ........................................................ Tires ............................................................................. Capacity - fuel................................................................ TECHNICAL DATA - FORK................................................... TECHNICAL DATA - SHOCK ABSORBER .............................. TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...
MEANS OF REPRESENTATION 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.
IMPORTANT INFORMATION 8 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only. Service A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis are properly carried out as described in the owner's manual.
IMPORTANT INFORMATION 9 Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage. Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be glad to advise you.
IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Secure the motorcycle against falling over or rolling away using straps or other suitable devices. 10 Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and conflicts.
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IMPORTANT INFORMATION 12 Overview of labels 2.
IMPORTANT INFORMATION 1 Information on emission control 2 Type label, Canada 3 Information on operating substances and tires 4 Information on noise emission 5 Information on preparing for use 6 Information on chain tension 6 Information on suspension setting 7 Information on the fuel evaporation system 8 Type label, USA 13 C00204-01 Information on emission control
IMPORTANT INFORMATION 14 C00205-01 Type label, Canada B00694-01 Information on operating substances and tires
IMPORTANT INFORMATION 15 B00695-01 Information on noise emission Information on preparing for use 600961-01
IMPORTANT INFORMATION Information on chain tension 600966-01 Information on suspension setting C00207-01 16
IMPORTANT INFORMATION 17 C00206-01 Information on the fuel evaporation system C00208-01 Type label, USA Notes/warnings Pay close attention to the notes/warnings.
IMPORTANT INFORMATION 18 Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
IMPORTANT INFORMATION 19 Reporting safety defects If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
IMPORTANT INFORMATION 20 1 Removal or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2 Removal or puncturing of any part of the intake system. 3 Lack of proper maintenance. 4 Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
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VIEW OF VEHICLE 22 View of vehicle, front left side (example) 3.
VIEW OF VEHICLE 23 1 Combination instrument ( p. 35) 2 Rear mirror 3 Clutch lever ( 4 Seat 5 Handrails ( 6 Level viewer, engine oil 7 Shift lever ( 8 Engine number ( 9 Shock absorber rebound adjustment 10 Compression damping of the shock absorber ( p. 30) p. 48) p. 51) p. 28) p.
VIEW OF VEHICLE 24 View of vehicle, rear right side (example) 3.
VIEW OF VEHICLE 25 1 Seat lock ( p. 49) 2 Light switch ( 2 Headlight flasher switch ( 2 Turn signal switch ( 2 Horn button ( 3 Filler cap 4 Emergency OFF switch ( 4 Electric starter button ( 5 Hand brake lever ( 6 Fork rebound setting and spring preload setting 7 Passenger footrests ( 8 Shock absorber setting, spring preload adjuster 9 Foot brake lever ( 10 Chassis number/type label ( 11 Fork compression adjustment p. 31) p. 32) p. 32) p. 33) p. 34) p. 35) p. 30) p.
SERIAL NUMBERS 26 Chassis number/type label 4.1 The chassis number 1 is stamped on the frame behind the steering head on the right. B00664-10 The type label for the USA 2 is fitted on the frame tube on the right.
SERIAL NUMBERS 27 The type label for Canada 3 is fitted on the frame tube on the left. 601115-10 Key number 4.2 The Code number 1 key 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.
SERIAL NUMBERS 28 Engine number 4.3 The engine number 1 is stamped on the left side of the engine under the engine sprocket. B00120-10 Fork part number 4.4 The fork part number 1 is stamped on the inner side of the fork stub.
SERIAL NUMBERS 29 Shock absorber part number 4.5 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side.
CONTROLS 30 Clutch lever 5.1 The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B00608-10 Hand brake lever 5.2 The hand brake lever 1 is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.
CONTROLS 31 Throttle grip 5.3 The throttle grip 1 is fitted on the right side of the handlebar. B00655-10 Light switch 5.4 The light switch 1 is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – The light switch is turned upwards. In this position, the high beam and tail light are switched on.
CONTROLS 32 Headlight flasher switch 5.5 The headlight flasher switch 1 is fitted on the left side of the handlebar. Possible states • Headlight flasher switch in basic position • Headlight flasher switch pressed – The headlight flasher switch (high beam) is operated in this position. B00685-10 Turn signal switch 5.6 The turn signal switch 1 is fitted on the left side of the handlebar. Possible states Turn signal off Left turn signal on – The turn signal switch is pressed to the left.
CONTROLS 33 Horn button 5.7 The horn button 1 is fitted on the left side of the handlebar. Possible states • Horn button • Horn button in basic position pressed – The horn is operated in this position. B00656-12 Ignition/steering lock 5.8 The ignition/steering lock is in front of the upper triple clamp. Info The ignition may only be switched on using a black ignition key. Use the orange programming key to activate and deactivate the black ignition key.
CONTROLS 34 Immobilizer 5.9 The electronic immobilizer secures the vehicle against unauthorized use. The immobilizer is activated automatically and the engine electronics are locked when the ignition key is withdrawn. The red warning lamp flashes at 15 second intervals after one minute. The red warning lamp can also indicate errors by flashing. Info The ignition key contains electronic components.
CONTROLS 35 Electric starter button 5.11 The electric starter button 1 is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button in basic position pressed – The electric starter is actuated in this position. B00657-11 Combination instrument 5.12 The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas.
CONTROLS 36 Combination instrument - function buttons 5.13 You can change the display mode with the MODE button 1. Possible display modes are the distance traveled (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2), and the ambient temperature. Press the SET button 2 to reset the trip master 1 function (TRIP 1) and trip master 2 function (TRIP 2) to 0.0. The ABS can be switched off using button 3. 400886-10 Combination instrument - tachometer 5.
CONTROLS 37 Combination instrument - indicator lamps 5.15 The indicator lamps offer additional information about the operating state of the motorcycle. Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up green – The transmission is shifted to idle. 400889-01 The high beam indicator light lights up blue – The high beam is switched on.
CONTROLS 38 Combination instrument - display 5.16 When you switch on the ignition, all display segments light up for one second as a function test. 400892-01 LEnGth Following the display function test, the LEnGth wheel circumference is shown for one second. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series production tire. The display then changes to the last selected mode.
CONTROLS 39 Combination instrument - speedometer 5.17 The speed 1 is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 Setting kilometers or miles 5.18 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary.
CONTROLS 40 – Switch on the ignition by turning the ignition key to the ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h. position. 400893-10 Combination instrument - time 5.19 The time is shown in area 1 of the display. Info After reconnecting the battery or changing the fuse, the time must be reset. 400893-11 Setting the clock 5.20 Condition The motorcycle is stationary.
CONTROLS 41 – Switch on the ignition by turning the ignition key to the ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. – Press the MODE button to set the hour. – Press the SET button to set the minute. – Keep the MODE button and the SET button pressed simultaneously. position. The time display begins to flash. 400893-12 The time is set. Combination instrument - ODO display 5.
CONTROLS 42 – Switch on the ignition by turning the ignition key to the ON – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. position. The TRIP 1 display is set to 0.0. 400840-01 Combination instrument - setting/resetting TRIP 2 5.23 Info The TRIP 2 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.
CONTROLS 43 Combination instrument - TRIP F display 5.24 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 400842-01 Combination instrument - ambient temperature display 5.25 The ambient temperature 1 is displayed in °C or °F.
CONTROLS 44 Setting the temperature units 5.26 Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to the ON – Press the MODE button repeatedly until the ambient temperature is active. – Keep the MODE button pressed until the display mode changes from °C to °F or from °F to °C. position. 400893-14 Combination instrument - warning of slippery roads 5.27 The ice symbol The ice symbol specified value.
CONTROLS 45 Combination instrument - coolant temperature indicator 5.28 The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temperature warning lamp lights up. Possible states • Engine cold – Up to five bars light up. • The engine is warm – Six to eleven bars light up. • Engine hot – All twelve bars flash. 700124-01 Hazard warning flasher switch/hazard warning flasher 5.
CONTROLS 46 Socket for electrical accessories 5.30 Socket 1 for electrical accessories is fitted next to the ignition/steering wheel lock on the left. It is connected to the battery without an additional switch. Socket for electrical accessories Voltage 12 V Maximum current consumption 10 A B00614-10 Opening the filler cap 5.31 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first.
CONTROLS 47 Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Lift the cover of the filler cap 1 and insert the ignition key. Note Danger of damage Ignition key breakage. – – To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced. Turn the ignition key 90° counterclockwise and remove the filler cap.
CONTROLS 48 Handrails 5.33 The handrails 1 are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the handrails during the trip. 600923-10 Luggage rack plate 5.34 The luggage rack plate 1 is located behind the seat. The base plate of a luggage system can be mounted on the luggage rack plate (optional). The luggage rack plate may not be loaded with more than the specified weight. Maximum permissible load of luggage rack plate 8 kg (18 lb.
CONTROLS 49 Seat lock 5.35 Seat lock 1 is located at the rear under the tail light. It can be locked with the ignition key. 600922-10 Tool set 5.36 The tool set 1 is located in the storage compartment under the seat.
CONTROLS 50 Helmet lock 5.37 Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle. – Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out. The steel cable 1 in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen. B00687-10 Passenger footrests 5.38 The passenger footrests can be folded up and down.
CONTROLS 51 Shift lever 5.39 Shift lever 1 is mounted on the left side of the engine. B00120-11 The gear positions can be seen in the photograph. The neutral or idle position N is between the first and second gear.
CONTROLS 52 Foot brake lever 5.40 Foot brake lever 1 is located in front of the right footrest. The rear brake is activated using the foot brake lever. B00122-10 Side stand 5.41 The side stand 1 is located on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions.
PREPARING FOR USE 53 Information on first use 6.1 Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing present an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
PREPARING FOR USE 54 – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. – Before your first trip, read the entire operating instructions carefully. – Familiarize yourself with the controls. – Adjust the basic position of the clutch lever. ( – Adjust the basic position of hand brake lever. ( – Adjust the basic position of foot brake lever. ( – Get used to handling the vehicle on empty suitable terrain before making a longer trip.
PREPARING FOR USE 55 Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. – Mount and secure suitcase and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. – Adapt your speed according to your payload. If the motorcycle is loaded with luggage, ride more slowly. Maximum speed with luggage 130 km/h (80.
PREPARING FOR USE 56 – If you are carrying baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. – Do not exceed the maximum permissible total weight and the axle loads. Guideline Maximum permissible total weight 400 kg (882 lb.) Maximum permissible front axle load 160 kg (353 lb.) Maximum permissible rear axle load 250 kg (551 lb.
RIDING INSTRUCTIONS 57 Checks and maintenance measures when preparing for use 7.1 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 front brake fluid level. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( – Check the rear brake linings. ( – Check that the brake system is functioning properly.
RIDING INSTRUCTIONS 58 Starting 7.2 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
RIDING INSTRUCTIONS 59 Info Do not press the electric starter button until the function test of the combination instrument 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 starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again. This motorcycle is equipped with a safety start system.
RIDING INSTRUCTIONS Starting off 7.3 – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding 7.4 Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
RIDING INSTRUCTIONS 61 Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.
RIDING INSTRUCTIONS 62 Note Engine damage Engine overheating. – If the coolant temperature warning lamp lights up, stop the vehicle and switch off the engine. Let the engine cool, check the coolant level in the radiator, and correct it if necessary. If you continue riding while the coolant temperature warning lamp is lit, the engine may be damaged. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
RIDING INSTRUCTIONS 63 – Switch off the engine if you expect to be standing for a long time. – If the FI warning lamp (MIL) lights up during a trip, stop immediately. When you shift to neutral, the FI warning lamp (MIL) starts to flash. Info From the flashing rhythm, you can derive a two-digit number, the so-called flashing code. The flashing code tells you which component has a fault. – If the ice symbol appears on the combination instrument, roads may be icy.
RIDING INSTRUCTIONS 64 Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. Warning Danger of accidents Greater stopping distance due to ABS. – Braking should be appropriate to the driving situation and the road conditions. Warning Danger of accidents Excessively hard braking causes the wheels to lock.
RIDING INSTRUCTIONS – 65 On long downhill stretches, use the braking effect of the engine. Do this by changing down two gears, but do not race the engine. You will require less braking force and the brakes will not overheat. Stopping, parking 7.6 Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the vehicle, lock the steering and remove the ignition key.
RIDING INSTRUCTIONS – Apply the brakes. – Shift the transmission to neutral. – Switch off the ignition by turning the ignition key to the OFF 66 position. Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery is soon discharged. Therefore, always switch off the engine with the ignition key; the emergency OFF switch is provided for emergency situations only.
RIDING INSTRUCTIONS 67 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Switch off the engine.
SERVICE SCHEDULE 68 Service schedule 8.1 K10N K75A K150A K300A Check that the electrical equipment is functioning properly. • • • • Read out the trouble code memory using the KTM diagnostics tool. x Check the measured service values with the KTM diagnostics tool. x Change the engine oil and filter, clean the oil screens. x ( p. 168) Check the oil jet for the clutch lubrication. x • • • • • • • • • • • • Check the front brake linings. ( • • • • • Check the front brake discs.
SERVICE SCHEDULE 69 K10N Clean the dust boots of the fork legs. Check the front brake fluid level. ( Bleed the fork legs. ( p. 101) • p. 83) Check the steering head bearing play. • K75A K150A K300A • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Change the spark plugs. x Check the valve clearance. x Check all hoses (e.g. fuel, cooling, bleeding, drainage, ...) and sleeves for cracking, leaks, and incorrect routing.
SERVICE SCHEDULE Check the headlight setting. ( 70 p. 148) Check the radiator fan operation. x Final inspection: Check the vehicle of roadworthiness and take a test ride. Read out the fault memory after a test ride using the KTM diagnostics tool. Make the service entries in the KTM DEALER.NET and service record. K10N: Once after 1,000 km (621.
TUNING THE CHASSIS 71 Fork/shock absorber 9.1 The fork and the shock absorber offer many options of adapting the suspension to your riding style and the payload. Info 700587-01 To help you adapt the vehicle, we have summarized our findings in Table 1. You can find the table on the air filter box after you remove the seat. In all settings except for the spring preload of the shock absorber, the value is adjusted by first turning the screw all the way in and then setting the value.
TUNING THE CHASSIS 72 – Turn adjusting screws 1 clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping B00617-10 Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
TUNING THE CHASSIS 73 – Turn adjusting screws 1 clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping B00618-10 Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
TUNING THE CHASSIS 74 – Turn adjusting screws 1 clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of turns according to the fork type. Guideline Spring preload - Preload Adjuster B00618-11 Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload; turn counterclockwise to reduce spring preload.
TUNING THE CHASSIS 75 Compression damping of the shock absorber 9.5 C00134-01 The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly.
TUNING THE CHASSIS 76 – Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click. Info Do not loosen nut 2! – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed C00134-10 Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
TUNING THE CHASSIS 77 – Turn adjusting screw 1 clockwise all the way using a socket wrench. Info Do not loosen nut 2! – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed C00134-11 Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Adjusting the rebound damping of the shock absorber 9.
TUNING THE CHASSIS 78 – Turn adjusting screw 1 clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping C00135-10 Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Adjusting the spring preload of the shock absorber 9.
TUNING THE CHASSIS 79 – Remove screw 1 and take off the brake line guide. Info The brake line guide must always be removed to avoid damage to the brake line. C00136-10 – Push the brake lines carefully to the side. – Turn the Preload Adjuster counterclockwise all the way. 6 mm (0.24 in) Hexagon socket wrench (tool set) – Turn it clockwise by the number of turns corresponding to the shock absorber type and use.
TUNING THE CHASSIS 80 – Position the brake line guide and brake line. Info Watch out for the holding lug of the brake line guide. – Mount and tighten screw 1. Guideline Screw, brake line holder C00136-10 EJOT PT K60x20 2 Nm (1.
SERVICE WORK ON THE CHASSIS 81 Raising the motorcycle with the front wheel stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Preliminary work – Raise the motorcycle with the rear wheel stand. ( p. 82) Main work – Move the handlebar to the straight-ahead position. Align the front wheel stand with the fork legs using the adapters. Front wheel stand (61029055300) Info Always raise the rear of the motorcycle first.
SERVICE WORK ON THE CHASSIS Raising the motorcycle with the rear wheel stand 10.3 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the lifting bushings on the swingarm. – Insert the adapter in the rear wheel stand. Adapter (61029055120) Rear wheel stand (61029055400) – Stand the motorcycle upright, align the wheel stand with the swingarm and the adapters, and lift the motorcycle.
SERVICE WORK ON THE CHASSIS Bleeding the fork legs 10.5 Preliminary work – Lean the motorcycle on the side stand. Main work – Remove bleeder screws 1 briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten the bleeder screws. Info Carry out this operation on both fork legs. B00621-10 Removing the seat 10.6 600922-10 – Insert the ignition key in the seat lock 1 and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards.
SERVICE WORK ON THE CHASSIS 84 Mounting the seat 10.7 – Position front recesses 1 of the seat on the oval head screws of the fuel tank, lower the rear and simultaneously push it forward. Both lugs 2 must hook into the frame and locking bolt 3 must be inserted into the lock housing. The seat engages with an audible click. – Finally, check that the seat is correctly mounted. B00624-10 Mounting the helmet lock on the vehicle 10.
SERVICE WORK ON THE CHASSIS 85 Reinstalling the fuel tank 10.9 Preliminary work – Remove the seat. ( – p. 83) Remove the mask spoiler. ( p. 87) Main work – Remove screws 1 and the spoiler on both sides. 304308-10 – Remove screw 2 on both sides. Info The fuel hoses do not need to be disconnected. – B00670-11 Carefully push the fuel tank back.
SERVICE WORK ON THE CHASSIS 86 Positioning the fuel tank 10.10 Main work – Carefully push the fuel tank forward. The fuel tank fixations must engage in the recesses. – Install and tighten screw 1 with the bearing sleeve and rubber bushing on both sides. Guideline Remaining chassis screws M8 – Check the routing of the fuel lines. – Position the spoilers on both sides. Mount and tighten screws 2. 25 Nm (18.
SERVICE WORK ON THE CHASSIS Removing the mask spoiler 10.11 – Remove screws 1. – Remove screws 2. – Remove the mask spoiler.
SERVICE WORK ON THE CHASSIS – Remove screws 3. – Remove the inside trim of the mask spoiler. – Repeat the operation on the opposite side. – Position the inside trim of the mask spoiler. – Mount and tighten screws 1. 700633-01 Installing the mask spoiler 10.
SERVICE WORK ON THE CHASSIS – Position the mask spoiler. – Mount and tighten screws 2. – Mount and tighten screws 3. – Repeat the operation on the opposite side.
SERVICE WORK ON THE CHASSIS 90 Checking the chain for dirt 10.13 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 90) 400678-01 Cleaning the chain 10.14 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.
SERVICE WORK ON THE CHASSIS 91 Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( – p. 209) After drying, apply chain spray. Chain lube for road use ( p. 209) 400725-01 Checking the chain tension 10.15 Warning Danger of accidents Danger caused by incorrect chain tension.
SERVICE WORK ON THE CHASSIS 92 Main work – Shift the transmission to neutral. – In the area after the chain sliding guard, press the chain upward toward the link fork and measure chain tension A. Info The upper chain section B must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. 700570-01 Chain tension » 7 mm (0.28 in) If the chain tension does not meet specifications: – Adjust the chain tension. ( p. 92) Adjusting the chain tension 10.
SERVICE WORK ON THE CHASSIS 93 Main work – Loosen nut 1. – Loosen nuts 2. – Adjust the chain tension by turning the adjusting screws 3 on the left and right. Guideline Chain tension 7 mm (0.28 in) Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjuster 4 are in the same position in relation to reference marks C. The rear wheel is then correctly aligned. Info The upper chain section must be taut.
SERVICE WORK ON THE CHASSIS 94 Checking the chain, rear sprocket, engine sprocket and chain guide 10.17 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Replace the rear sprocket or engine sprocket. x Info The rear sprocket, engine sprocket and chain should always be changed together.
SERVICE WORK ON THE CHASSIS 95 – Shift the transmission to neutral. – Pull the lower chain section with specified weight A. Guideline Weight, chain wear measurement – 15 kg (33 lb.) Measure the distance B of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance B at the longest chain section » 272 mm (10.71 in) If distance B is greater than the specified measurement: – Replace the chain.
SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If there is no gap between the chain and the upper edge of the screw: – – 96 Change the chain sliding guard. x Check the chain sliding guard for tightness. » If the chain sliding guard is loose: – Tighten the chain sliding guard. Guideline B00653-01 – M5 5 Nm (3.7 lbf ft) – Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™ Check the chain sliding piece for wear.
SERVICE WORK ON THE CHASSIS 97 Adjusting the basic position of the clutch lever 10.18 Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.
SERVICE WORK ON THE CHASSIS 98 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1. – Remove cover 2 with membrane 3. – Check the fluid level. Fluid level below container rim » If the coolant level does not meet specifications: – B00672-10 Correct the fluid level of the hydraulic clutch. Hydraulic fluid (15) ( – 4 mm (0.16 in) p. 208) Position the cover with the membrane. Mount and tighten the screws.
BRAKES 99 ABS/antilock brake system 11.1 The ABS unit 1, which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. The front and rear wheels each have a wheel speed sensor 2.
BRAKES 100 Button 4 can be used to switch ABS off manually (see Starting). Adjusting the basic position of the hand brake lever 11.2 – Pull the hand brake lever forward. – Adjust the basic setting of the hand brake lever to your hand size by turning adjusting wheel 1. Info Do not make any adjustments while riding! B00627-10 Checking the front brake discs 11.3 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay.
BRAKES 101 – Check the thickness of the brake disc in several places to see if it conforms to measurement A. Info Wear reduces the thickness of the brake discs in area 1 of the brake discs. Brake discs - wear limit Front » 100135-10 If the brake disc thickness is less than the specified value: – – 4.5 mm (0.177 in) Change the brake discs. x Check the brake discs for damage, cracking and deformation. » If the brake discs exhibit damage, cracking or deformation: – Change the brake discs.
BRAKES 102 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in the brake fluid reservoir 1. » If the brake fluid is below the MIN marking: – Add front brake fluid. x( p. 102) B00628-10 Adding front brake fluid 11.5 x Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
BRAKES 103 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 Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces. Use only clean brake fluid from a sealed container. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws.
BRAKES 104 Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable. Check the brake linings regularly. – Check all brake linings on both brake calipers to ensure they have minimum thickness A. ≥ 1 mm (≥ 0.
BRAKES 105 – Move the foot brake lever back and forth between the end stop and the contact to the piston rod and check free travel A. Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The piston rod should not move. » 600921-10 If the free travel does not meet specifications: – Adjust the free travel to the specified value. Adjusting the basic position of the foot brake lever 11.8 Warning Danger of accidents Brake system failure.
BRAKES 106 Checking the rear brake disc 11.9 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the brake disc in several places to see if it conforms to measurement A. Info Wear reduces the thickness of the brake disc in area 1 of the brake disc.
BRAKES 107 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.) – Stand the vehicle upright. – Check the brake fluid level of the brake fluid reservoir. » If the fluid level reaches the MIN mark 1: – Add rear brake fluid. x( p. 107) 304306-10 Adding rear brake fluid 11.11 x Warning Danger of accidents Failure of the brake system.
BRAKES 108 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Avoid contact between brake fluid and painted parts.
BRAKES 109 – Add brake fluid to level A. Brake fluid DOT 4 / DOT 5.1 ( – p. 206) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 304305-10 Checking the rear brake linings 11.12 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.
BRAKES 110 – Check the brake linings for minimum thickness A. ≥ 1 mm (≥ 0.04 in) Minimum thickness A » If the minimum thickness is less than specified: – – » x If damage or wear is encountered: – B00631-01 Change the rear brake linings. Check the brake linings for damage and cracking. Change the rear brake linings.
WHEELS, TIRES Removing the front wheel 12.1 111 x Preliminary work – Raise the motorcycle with the rear wheel stand. ( – Raise the motorcycle with the front wheel stand. ( p. 82) p. 81) Main work – Take the speed sensor cable out of the clamp. – Remove screw 1 and pull wheel speed sensor 2 out of the hole with the sleeve. – Remove screws 3 from both brake calipers. – Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc.
WHEELS, TIRES Installing the front wheel 12.2 112 x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Check the wheel bearing for damage and wear. » If the wheel bearing is broken or worn: – – Replace the wheel bearing. x Clean, grease, and mount the left and right spacers and the shaft seal rings. Long-life grease ( p.
WHEELS, TIRES 113 – Slide the sleeve onto the wheel speed sensor 3 and push them into the hole together. Mount and tighten screw 4. Guideline Screw, wheel speed sensor B00632-11 M6 6 Nm (4.4 lbf ft) Loctite® 243™ – Fasten the speed sensor cable in the bracket. – Position the brake calipers and check that the brake linings are seated correctly. – Mount screws 5 on both brake calipers but do not tighten yet.
WHEELS, TIRES 114 – Pull the front brake and compress the fork powerfully a few times. – Tighten screws 6. The fork legs straighten. Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) B00686-10 Removing the rear wheel 12.3 x Preliminary work – Raise the motorcycle with the rear wheel stand. ( p.
WHEELS, TIRES 115 Main work – Remove screw 1 and pull wheel speed sensor 2 out of the hole. – Remove nut 3. Remove chain adjuster 4. – Pull out wheel spindle 5 to the point where the chain adjuster is no longer in contact with the adjusting screw. – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. – Withdraw the wheel spindle. – Pull the rear wheel backward until the brake caliper support hangs free between the brake disc and the wheel rim.
WHEELS, TIRES 116 – Take the rear wheel carefully out of the swingarm without damaging the rim and/or brake disc. Info Do not operate the foot brake when the rear wheel is removed. Installing the rear wheel 12.4 x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake.
WHEELS, TIRES 117 Long-life grease ( p. 210) – Clean the fixing locations on the brake caliper support and swingarm. – Engage the counter bearing of the brake caliper support A and swingarm. Carefully lift the rear wheel into the swingarm and engage the brake disc. Lay the chain on the rear sprocket and mount the wheel spindle. – Mount chain adjuster 2 and nut 3. Info Mount the left and right chain adjusters in the same position.
WHEELS, TIRES 118 Checking rear hub shock absorbers 12.5 x Info The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out during operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged. Preliminary work – Raise the motorcycle with the rear wheel stand. ( – Remove the rear wheel. x( p. 82) p. 114) Main work – Remove the rear sprocket carrier.
WHEELS, TIRES 119 Checking the tire condition 12.6 Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels. – The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
WHEELS, TIRES 120 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tires exhibit cuts, run-in objects or other damage: – – Change the tires. Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth 400602-10 » If the tread depth is less than the minimum permissible depth: – – ≥ 2 mm (≥ 0.08 in) Change the tires. Check the age of the tires.
WHEELS, TIRES 121 – Remove the dust cap. – Check the tire air pressure when the tires are cold. Tire air pressure, solo Front 2.4 bar (35 psi) Rear 2.4 bar (35 psi) Tire air pressure with passenger/full payload 400695-01 » 2.4 bar (35 psi) Rear 2.6 bar (38 psi) If the tire pressure does not meet specifications: – – Front Correct the tire pressure. Mount the dust cap. Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is faulty.
ELECTRICAL SYSTEM Removing the battery 13.1 122 x Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open flames. Charge only in well-ventilated areas. – In the event of skin contact, rinse with large amounts of water.
ELECTRICAL SYSTEM 123 Main work – Disconnect negative (minus) cable 1 of the battery. B00637-10 B00638-10 – Remove positive terminal cover 2. – Disconnect the positive (plus) cable 3 of the battery. – Detach rubber band 4. – Pull the battery up and out of the battery rack.
ELECTRICAL SYSTEM Installing the battery 13.2 124 x Main work – Position the battery in the battery rack. Info The terminals of the battery must face in the direction of travel. – Attach rubber band 1. – Reconnect the positive (plus) 2 cable of the battery. – Position positive terminal cover 3. – Reconnect the negative (minus) cable 4 of the battery. B00638-11 B00637-11 Subsequent work – Mount the seat. ( – Set the clock. ( p. 84) p.
ELECTRICAL SYSTEM Recharging the battery 13.3 125 x Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open flames. Charge only in well-ventilated areas. – In the event of skin contact, rinse with large amounts of water.
ELECTRICAL SYSTEM 126 Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity.
ELECTRICAL SYSTEM 127 Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid 1. Charge the battery to no more than 10% of the capacity specified on battery housing 2. – Switch off the charger after charging. Reconnect the battery.
ELECTRICAL SYSTEM 128 Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. Preliminary work – Switch off all power consumers and the engine. – Remove the seat. ( p. 83) Main work – Remove protection covers 1. – Remove the faulty main fuse 2. Info A defective fuse can be identified by the burned-out fuse wire A. A reserve fuse 3 is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p.
ELECTRICAL SYSTEM 129 Changing the ABS fuses 13.5 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box. Preliminary work – Switch off all power consumers and switch off the engine.
ELECTRICAL SYSTEM 130 To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse 2. – Insert the new fuse. Fuse (58011109130) – Mount the protection cap. B00639-11 Follow-up work – Mount the seat. ( p. 84) Changing the fuses of individual power consumers 13.6 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
ELECTRICAL SYSTEM 131 Main work – Open fuse box cover 1. – Check the fuses. Info A faulty fuse can be identified by the burned-out fuse wire A. – Remove the faulty fuse.
ELECTRICAL SYSTEM 132 Tip Insert a spare fuse so that it is available if needed. – Close the fuse box cover. Follow-up work – Mount the seat. ( p. 84) Changing the headlight bulb 13.7 Note Damage to reflector Reduced luminance. – 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. Preliminary work – Switch off all power consumers and switch off the engine. Main work – Remove the cover.
ELECTRICAL SYSTEM 133 – Disconnect connector 1. – Remove rubber cap 2. – Detach retaining clamps 3. – Remove headlight bulb 4. – Position the new headlight bulb in the headlight housing. B00673-10 Low beam/high beam (H4/socket P43t) ( p. 197) Info Insert the headlight bulb so that the bayonet lugs latch into the slots. B00674-10 B00673-10 – Position the retaining clamps. – Mount rubber cap 2. – Plug in connector 1.
ELECTRICAL SYSTEM 134 – Mount the cover. – Check that the lighting is functioning properly. B00668-01 Changing the parking light bulb 13.8 Note Damage to reflector Reduced luminance. – 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. Preliminary work – Switch off all power consumers and switch off the engine. Main work – Remove the cover.
ELECTRICAL SYSTEM 135 – Pull cable guide 1 and the socket of the parking light carefully out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9.5d) ( p. 197) – Carefully position the socket with the bulb in the housing. – Mount the cable guide. – Mount the cover. – Check that the lighting is functioning properly.
ELECTRICAL SYSTEM 136 Changing the turn signal bulb 13.9 Note Damage to reflector Reduced luminance. – 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. – Remove the screw on the rear of the turn signal housing. – Carefully remove diffuser 1. – Press bulb 2 carefully into the socket, turn it counterclockwise by about 30°, and pull it out of the socket.
ELECTRICAL SYSTEM 137 Main work – Remove screws 1. – Remove the grab handles. – Remove screws 2 on the left and right heat protectors. – Remove the heat protectors.
ELECTRICAL SYSTEM 138 – Remove screws 3 on the left and right rear side parts. – Remove screws 4. – Remove the rear side parts. – Remove screws 5. – Remove the rear top part.
ELECTRICAL SYSTEM 139 – Turn bulb socket 6 counterclockwise all the way and take it out of the tail light. – Push the bulb carefully into the socket, turn it counterclockwise, and pull it out of the socket. – Press the new bulb carefully into the socket and turn it clockwise until it stops. Brake light (P21W/socket BA15s) – Insert the bulb socket into the tail light and turn clockwise until it stops. – Check that the brake light system is functioning properly. – Position the rear top part.
ELECTRICAL SYSTEM 140 – Position the rear side parts. – Mount and tighten screws 3 on the left and right rear side parts. Guideline Screw, rear side part – EJOT Altracs 50x16 Initial screw connection 3.3 Nm (2.43 lbf ft) Subsequent screw connection 2 Nm (1.5 lbf ft) Remaining chassis screws M5 5 Nm (3.7 lbf ft) Remaining frame bolts EJOT PT K50x12 T20 1.2 Nm (0.89 lbf ft) Mount and tighten screws 4. Guideline B00643-10 – Position the heat protectors.
ELECTRICAL SYSTEM 141 – Position the grab handles. – Mount and tighten screws 1. Guideline Screw, handrail M8 20 Nm (14.8 lbf ft) B00641-10 Follow-up work – Mount the seat. ( p. 84) Changing the tail light bulbs 13.11 Note Damage to reflector Reduced luminance. – 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. Preliminary work – Remove the seat. ( p.
ELECTRICAL SYSTEM 142 Main work – Remove screws 1. – Remove the grab handles. – Remove screws 2 on the left and right heat protectors. – Remove the heat protectors.
ELECTRICAL SYSTEM 143 – Remove screws 3 on the left and right rear side parts. – Remove screws 4. – Remove the rear side parts. – Remove screws 5. – Remove the rear top part.
ELECTRICAL SYSTEM 144 – Pull bulb sockets 6 carefully out of the bracket. – Remove the bulb. – Position a new light bulb in the socket. Tail light (W5W/socket W2.1x9.5d) – Carefully position the sockets with the bulbs into the bracket in the tail light. – Check that the tail light bulbs are functioning properly. – Position the rear top part. – Mount and tighten screws 5. B00646-10 Guideline B00644-10 Remaining chassis screws M5 5 Nm (3.
ELECTRICAL SYSTEM 145 – Position the rear side parts. – Mount and tighten screws 3 on the left and right rear side parts. Guideline Screw, rear side part – EJOT Altracs 50x16 Initial screw connection 3.3 Nm (2.43 lbf ft) Subsequent screw connection 2 Nm (1.5 lbf ft) Remaining chassis screws M5 5 Nm (3.7 lbf ft) Remaining frame bolts EJOT PT K50x12 T20 1.2 Nm (0.89 lbf ft) Mount and tighten screws 4. Guideline B00643-10 – Position the heat protectors.
ELECTRICAL SYSTEM 146 – Position the grab handles. – Mount and tighten screws 1. Guideline Screw, handrail M8 B00641-10 Follow-up work – Mount the seat. ( p. 84) Changing the license plate lamp 13.12 Main work – Remove screws 1. – 700602-01 Remove the license plate lamp cover. 20 Nm (14.
ELECTRICAL SYSTEM 147 – Pull holder 2 carefully out of the bracket. – Remove the bulb. – Position a new light bulb in the holder. License plate lamp (W5W/socket W2.1x9.5d) ( p. 198) – Carefully position the holder with the bulb into the bracket. – Position the cover. – Mount and tighten screws 1. 700603-01 700602-01 Follow-up work – Check that the license plate lamp is functioning properly.
ELECTRICAL SYSTEM 148 Checking the headlight setting 13.13 A 0 – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the level of the center of the headlight. – Make another mark at a distance of B under the first mark. Guideline 0 B Distance B – 5 cm (2 in) Park the vehicle at a distance of A vertically in front of the wall and switch on the low beam headlight.
ELECTRICAL SYSTEM 149 Main work – Turn adjusting wheel 2 to adjust the headlight range. Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking the headlight adjustment). Info B00139-10 Turning up increases the range, while turning down decreases the range. Do not make any adjustments while riding! Activating/deactivating the ignition key 13.
ELECTRICAL SYSTEM 150 Loss of a black ignition key (second black ignition key available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Press the emergency OFF switch into the position – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position . 401184-10 FI warning lamp Immobilizer indicator lamp B00652-10 lights up.
ELECTRICAL SYSTEM 151 Immobilizer indicator lamp lights up, switches off briefly and flashes; the number of flashes equals the number of functional black ignition keys including the orange programming key. In this case, twice. – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. . The lost black ignition key is deactivated. The existing black ignition key is reactivated.
ELECTRICAL SYSTEM 152 – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. . All black ignition keys are deactivated. – Order a new black ignition key according to the key number on the KEYCODECARD and activate it. Activating the ignition key: – Press the emergency OFF switch into the position . – Insert the orange programming key in the ignition lock.
ELECTRICAL SYSTEM 153 The immobilizer indicator lamp lights up, switches off briefly and flashes; the number of flashes equals 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. . All black ignition keys are activated included in this job sequence are activated.
COOLING SYSTEM 154 Cooling system 14.1 The water pump 1 in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap. This permits the specified coolant temperature without causing any malfunctions. 125 °C (257 °F) B00676-10 Cooling takes place by means of the air stream and a radiator fan, which is controlled by a thermoswitch. The lower the speed, the less the cooling effect.
COOLING SYSTEM 155 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition The engine is cold.
COOLING SYSTEM 156 Alternative 2 Coolant (mixed ready to use) ( » p. 206) If there is no coolant in the compensating tank: – Check the cooling system for leaks. x Info Do not start up the motorcycle! – Fill/bleed the cooling system. x( – Mount cap 2 of the compensating tank. – Check the coolant level in the radiator. p. 159) The radiator must be completely filled. » If the coolant level does not meet specifications: – Correct the coolant level and determine the reason for the coolant loss.
COOLING SYSTEM 157 Checking the coolant level in the compensating tank 14.3 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.
COOLING SYSTEM 158 Alternative 2 Coolant (mixed ready to use) ( – » p. 206) Mount the cap of the compensating tank. If there is no coolant in the compensating tank: – Check the cooling system for leaks. x Info Do not start up the motorcycle! – Draining the coolant 14.4 Fill/bleed the cooling system. x( p. 159) x Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
COOLING SYSTEM 159 Main work – Place a suitable container under the radiator. – Remove radiator cap 1. – Remove screw 2. – Completely drain the coolant. – Mount screw 2 with a new seal ring and tighten it. Guideline Remaining chassis screws M6 10 Nm (7.4 lbf ft) B00680-10 – Place a suitable container under the engine. – Remove screw 3. – Completely drain the coolant. – Mount screw 3 with a new seal ring and tighten it. Guideline Screw, water pump cover M6 10 Nm (7.
COOLING SYSTEM 160 Preliminary work – Remove the seat. ( p. 83) – Remove the mask spoiler. ( – Reset the fuel tank. ( p. 87) p. 85) Main work – Ensure that the drain plug on the radiator and the water pump cover are tightened. – Remove bleeder screw 1. – Position the vehicle as shown and secure it against rolling. Height difference A must be reached. 700629-10 Guideline Height difference A 50 cm (19.
COOLING SYSTEM 161 – Remove the radiator cap and pour in coolant until it emerges without bubbles at the vent hole, and then immediately mount and tighten the bleeder screw 1. Alternative 1 Coolant ( p. 206) Alternative 2 Coolant (mixed ready to use) ( B00682-10 p. 206) – Fill the radiator completely with coolant. Mount the radiator cap. – Lean the vehicle on the side stand. – Check the coolant level in the compensating tank. ( p.
TUNING THE ENGINE 162 Checking the play in the throttle cable 15.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Play in throttle cable » 3… 5 mm (0.12… 0.2 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. x( p.
TUNING THE ENGINE Adjusting the play in the throttle cable 15.2 163 x – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the basic position. – Push back sleeve 1. – Loosen lock nut 2. – Set the play in the throttle cable by turning adjusting screw 3. Guideline Play in throttle cable B00666-10 3… 5 mm (0.12… 0.2 in) – Tighten lock nut 2. – Slide on sleeves 1. – Check the throttle grip for ease of movement.
TUNING THE ENGINE 164 Adjusting the ignition curve to the fuel quality 15.4 Preliminary work – Switch off the ignition by turning the ignition key to the OFF – Remove the seat. ( position. p. 83) To activate the ignition curve for low octane fuel: Note Engine failure Low-quality fuel damages the engine. – – Operate the vehicle with fuel with an octane rating below 95 (ROZ 95/RON 95/PON 91) for no more than one tank full. – The ignition curve must be adjusted to low octane fuel.
TUNING THE ENGINE 165 Checking the basic position of the shift lever 15.5 – Sit on the vehicle in the riding position and determine the distance A between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot » A 0 If the distance does not meet specifications: – Adjust the basic position of the shift lever. 400692-10 Adjusting the basic position of the shift lever 15.6 – 101172-10 10… 20 mm (0.39… 0.
TUNING THE ENGINE 166 – Clean gear teeth A of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure. – 101173-10 Mount and tighten the screw. Guideline Screw, shift lever M6 10 Nm (7.
SERVICE WORK ON THE ENGINE 167 Checking the engine oil level 16.1 Preliminary work Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and run it until it reaches operating temperature. Six bars of the temperature display light up.
SERVICE WORK ON THE ENGINE 168 Changing the engine oil and filter, cleaning the oil screens 16.2 x – Drain the engine oil and filter, clean the oil screens. – Fill up with engine oil. x( x( p. 168) p. 173) B00119-01 Draining the engine oil and filter, cleaning the oil screens 16.3 x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the oil drain plug 1 with the magnet and seal ring. – Fully drain the engine oil out of the engine. – Remove screws 2 and cover 3. – Pull oil screen 4 out of the engine case with pliers.
SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove oil drain plug 5. – Fully drain the engine oil out of the oil tank. – Remove screws 6 and move oil line 7 to one side. – Pull oil screen 8 out of the oil tank. – Remove screw connection 9 and move the oil line to one side. – Remove the screws. Remove the oil filter cover bk with the O-ring. – Pull oil filter bl out of the oil filter housing.
SERVICE WORK ON THE ENGINE 171 – Insert oil filter bl. – Lubricate the O-ring of the oil filter cover. – Mount the oil filter cover bk. Mount and tighten the screws. Guideline Remaining engine screws – M5 6 Nm (4.4 lbf ft) Position the oil line. Mount and tighten screw connection 9. Guideline Nut, oil line 700618-10 700614-10 M16x1.5 25 Nm (18.4 lbf ft) – Check seal ring bm of the oil screen for damage and correct seating. – Insert oil screen 8 into the oil tank.
SERVICE WORK ON THE ENGINE – 172 Position oil line 7. Mount and tighten screws 6. Guideline Remaining engine screws – M6 10 Nm (7.4 lbf ft) Mount oil drain plug 5 with the magnet and new seal and tighten. Guideline Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft) 700613-10 – Mount oil drain plug 1 with the magnet and new seal ring and tighten. Guideline Oil drain plug with magnet M22x1.5 35 Nm (25.
SERVICE WORK ON THE ENGINE Filling up with engine oil 16.4 173 x Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – The oil must be added in two steps. Engine oil B00683-10 3.0 l (3.2 qt.) External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 207) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 207) – Remove plug 1 and add engine oil to the top marking 2. – Mount the plug.
SERVICE WORK ON THE ENGINE 174 – Remove the plug. – Add engine oil to the top marking 2. – Mount the plug. Adding engine oil 16.5 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. The engine oil level must be corrected when the engine is warm. – Remove plug 1 and add engine oil to the top marking 2. Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p.
CLEANING, CARE 175 Cleaning motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
CLEANING, CARE 176 – After the motorcycle has been thoroughly cleaned with a gentle jet of water, it should be dried with compressed air and a cloth. Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – – Clean or dry dirty or wet brakes by riding and braking gently. After cleaning, ride the vehicle a short distance until the engine warms up, applying the brakes occasionally.
CLEANING, CARE 177 Checks and maintenance measures for winter operation 17.2 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 use. Warm water would enhance the corrosive effects of salt. – Clean the motorcycle. ( – Clean the brakes. p.
STORAGE 178 Storage 18.1 Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.
STORAGE 179 – Cover the motorcycle with a tarp or cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. Preparing for use after storage 18.2 401059-01 – Take the motorcycle off of the front wheel stand.
TROUBLESHOOTING 180 Faults Possible cause Action The engine does not turn when the starter button is pressed Operating error – Carry out the start procedure. ( Battery discharged – Recharge the battery. – Check the closed current. 1, or 5 fuse blown – Change the fuses of individual power consumers. ( p. 130) Main fuse burned out – Change the main fuse. ( Ignition/steering lock or emergency OFF switch defective – Check the emergency OFF switch.
TROUBLESHOOTING 181 Faults Possible cause Action Engine has too little power Air filter very dirty – Change the air filter. Defect in fuel injection system – Read out the fault memory using the KTM diagnostics tool. x x Engine overheats FI warning lamp (MIL) lights up/flashes Engine dies during a trip The ABS warning lamp lights up – Check the cooling system for leaks. – Check the antifreeze and coolant level. ( p. 154) Radiator fins very dirty – Clean radiator fins.
TROUBLESHOOTING 182 Faults Possible cause Action High oil consumption Engine oil level too high – Check the engine oil level. ( Engine oil too thin (low viscosity) – Change the engine oil and filter, clean the oil screens. ( p. 168) p. 167) x The headlight and tail light are not functioning Fuse 2 blown – Change the fuses of individual power consumers. ( p.
IMMOBILIZER BLINK CODE Blink code of immobilizer indicator lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Blink code of immobilizer indicator lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition ICU antenna malfunction Blink code of immobilizer indicator lamp 14 Immobilizer indicator lamp flashes 1x short, 1 second pause, 4x short Error level condition Malfunction in transponde
IMMOBILIZER BLINK CODE Blink code of immobilizer indicator lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition ICU is not activated Blink code of immobilizer indicator lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indicator lamp 32 Immobilizer indicator lamp flashes 3x short, 1 second pause, 2x shor
ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Circuit ignition pulse generator - circuit fault Blink code of FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle valve sensor circuit A - input signal too low Throttle valve sensor circuit A - input signal too high Blink code of FI warning lamp (MIL) 07 FI warning lamp (MIL) flashes 7x short Error level condition Throttle position sen
ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 12 FI warning lamp (MIL) flashes 1x long, 2x short Error level condition Coolant temperature sensor - input signal too low Coolant temperature sensor - input signal too high Blink code of FI warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Error level condition Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high Blink code of FI warning lamp (MIL) 14 FI warning lamp (
ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 18 FI warning lamp (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Blink code of FI warning lamp (MIL) 24 FI warning lamp (MIL) flashes 2x long, 4x short Error level condition Power supply - circuit fault Blink code of FI warning lamp (MIL) 25 FI warning lamp (MIL) flashes 2x long, 5x short Error level condition Side stand (A/D type) - malfunction in circuit Blink code of FI warning l
ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code of FI warning lamp (MIL) 38 FI warning lamp (MIL) flashes 3x long, 8x short Error level condition Ignition coil 1, cylinder 2 - circuit fault Blink code of FI warning lamp (MIL) 41 FI warning lamp (MIL) flashes 4x long, 1x short Error level condition Fuel pump control - interruption/short circuit to ground Fuel pump
ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 49 FI warning lamp (MIL) flashes 4x long, 9x short Error level condition Motor drive circuit A - circuit fault Blink code of FI warning lamp (MIL) 50 FI warning lamp (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Blink code of FI warning lamp (MIL) 53 FI warning lamp (MIL) flashes 5x long, 3x short Error level condition Fuel evaporation system - short circuit to ground or open circuit Fuel evaporation syste
ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 69 FI warning lamp (MIL) flashes 6x long, 9x short Error level condition Manifold absolute pressure sensor cylinder 2 - connection leaks Blink code of FI warning lamp (MIL) 81 FI warning lamp (MIL) flashes 8x long, 1x short Error level condition Immobilizer control unit - circuit fault Blink code of FI warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition Malfunction in CAN bus communication 190
TECHNICAL DATA - ENGINE 191 Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 999 cm³ (60.96 cu in) Stroke 62.4 mm (2.457 in) Bore 101 mm (3.98 in) Compression ratio 11.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter Exhaust 33 mm (1.3 in) Intake 38 mm (1.5 in) Valve clearance Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098… 0.0118 in) Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.
TECHNICAL DATA - ENGINE 192 5th gear 24:27 6th gear 27:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug NGK LKAR8BI9 Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump Idle speed 1,400… 1,600 rpm Cold start device Electric starter Capacity - engine oil 22.1 Engine oil 3.0 l (3.2 qt.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 193 Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) – Screw, oil spray tube M4 6 Nm (4.4 lbf ft) Loctite® 243™ Remaining engine screws M5 6 Nm (4.4 lbf ft) – Screw, bearing retainer M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, connecting angle on valve cover M5 3 Nm (2.2 lbf ft) Loctite® 243™ Screw, gear sensor M5 3 Nm (2.2 lbf ft) Loctite® 243™ Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™ Nut, cylinder head M6 8 Nm (5.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 194 Screw, valve cover M6 10 Nm (7.4 lbf ft) – Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™ Vacuum connection M6 2.5 Nm (1.84 lbf ft) Loctite® 243™ Oil jet M6x0.75 4 Nm (3 lbf ft) Loctite® 243™ Screw, camshaft bearing support M8 Step 1 10 Nm (7.4 lbf ft) Step 2 18 Nm (13.3 lbf ft) – Screw, clutch cover M8 15 Nm (11.1 lbf ft) – Screw, cylinder head M8 Step 1 18 Nm (13.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 195 Stud, cylinder head in engine case M10 20 Nm (14.8 lbf ft) – Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 60° – Spark plug M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) – Plus, cylinder head (2nd cylinder) M12x1.5 25 Nm (18.4 lbf ft) – Plug, oil filter housing M14x1.5 15 Nm (11.
TECHNICAL DATA - CHASSIS 196 Frame Lattice frame made of chrome molybdenum steel tubing, powdercoated Fork WP Suspension Up Side Down 4860 ROMA PA Shock absorber WP Suspension 4618 BAVP DCC PA Suspension travel Front 160 mm (6.3 in) Rear 180 mm (7.09 in) Brake system Front Double disc brake with radially screwed four-piston brake calipers, float-mounted brake discs Rear Single disc brake with dual-piston brake caliper, rigid-mounted brake disc Brake discs - diameter Front 305 mm (12.
TECHNICAL DATA - CHASSIS 197 Secondary drive ratio 17:41 Chain 5/8 x 5/16” X‑ring Steering head angle 65.6° Wheelbase 1,505±15 mm (59.25±0.59 in) Seat height, unloaded 855 mm (33.66 in) Ground clearance, unloaded 195 mm (7.68 in) Weight without fuel, approx. 198 kg (437 lb.) Maximum permissible front axle load 160 kg (353 lb.) Maximum permissible rear axle load 250 kg (551 lb.) Maximum permissible total weight 400 kg (882 lb.
TECHNICAL DATA - CHASSIS License plate lamp 198 W5W/socket W2.1x9.5d 12 V 5W Tires 24.2 Front tire Rear tire 120/70 ZR 17 M/C 58W TL Continental ContiSportAttack 180/55 ZR 17 M/C 73W TL Continental ContiSportAttack Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 24.3 Total fuel tank capacity, approx. Fuel reserve, approx. 19 l (5 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( 3.7 l (3.9 qt.) p.
TECHNICAL DATA - FORK 199 Fork part number 14.18.7K.43 Fork WP Suspension Up Side Down 4860 ROMA PA Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring preload - Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer(s) 384 mm (15.12 in) Spring rate Medium (standard) 7.
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7L.20 Shock absorber WP Suspension 4618 BAVP DCC PA Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.
TECHNICAL DATA - SHOCK ABSORBER Gas pressure 10 bar (145 psi) Fitted length 372 mm (14.65 in) Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( 201 p.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 202 Remaining frame bolts EJOT Delta PT 50x12 1.2 Nm (0.89 lbf ft) – Remaining frame bolts EJOT PT K50x12 T20 1.2 Nm (0.89 lbf ft) – Remaining frame bolts EJOT PT K50x18 T20 2 Nm (1.5 lbf ft) – Screw, brake line holder EJOT PT K60x20 2 Nm (1.5 lbf ft) – Screw, chain sliding piece EJOT PT K60x20 2 Nm (1.5 lbf ft) – Screw, combination instrument EJOT Delta PT 50x12 1 Nm (0.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 203 Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, fuel pump M6 6 Nm (4.4 lbf ft) – Screw, fuel tap M6 6 Nm (4.4 lbf ft) – Screw, holder on ABS unit M6 6 Nm (4.4 lbf ft) – Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, seat bracket, fuel tank M6 3.3 Nm (2.43 lbf ft) – Screw, splash protector M6 6 Nm (4.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 204 Screw, mask holder M8 15 Nm (11.1 lbf ft) Loctite® 243™ Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™ Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, spring holder on side stand bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, steering stem M8 20 Nm (14.8 lbf ft) – Screw, top triple clamp M8 20 Nm (14.8 lbf ft) – Remaining chassis nuts M10 45 Nm (33.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 205 – Nut, oil line M16x1.5 25 Nm (18.4 lbf ft) Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) – Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) – Nut, rear wheel spindle M25x1.5 90 Nm (66.
SUBSTANCES 206 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Guideline – Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming.
SUBSTANCES 207 Engine oil (SAE 10W/50) According to – JASO T903 MA ( – SAE ( p. 211) p. 211) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Fully synthetic engine oil Supplier Motorex® – Power Synt 4T Engine oil (SAE 5W/40) According to – JASO T903 MA ( – SAE ( p. 211) p.
SUBSTANCES 208 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 211) (SAE 2.
AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex® products. Supplier Motorex® – Protect & Shine High-luster polish for paint Guideline – KTM recommends Motorex® products.
AUXILIARY SUBSTANCES Long-life grease Guideline – KTM recommends Motorex® products. Supplier Motorex® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900 Universal oil spray Guideline – KTM recommends Motorex® products.
STANDARDS 211 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.
INDEX INDEX A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Antilock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 B Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 212 Brake light bulb changing . . . . . . . . . . . . .
INDEX 213 display, ambient temperature . function buttons . . . . . . . . . . indicator lamps . . . . . . . . . . kilometers or miles, setting . . ODO display . . . . . . . . . . . . . speed display . . . . . . . . . . . . tachometer . . . . . . . . . . . . . temperature units, setting . . . time . . . . . . . . . . . . . . . . . . TRIP 1 display, setting/resetting TRIP 2 display, setting/resetting TRIP F display . . . . . . . . . . . . warning of slippery roads . . . . Coolant draining . . . . . . . . .
INDEX 214 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Fuel tank positioning reinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuse individual power consumers, changing . . . . . . . . . . . . . . 130 Fuses, ABS changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX raising with the rear wheel stand . . . . . . . . . . . . . . . . . . . 82 taking off of the front wheel stand . . . . . . . . . . . . . . . . . . 81 taking off of the rear wheel stand . . . . . . . . . . . . . . . . . . 82 O Oil filter changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Oil screens cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 216 Shock absorber part number . . . Side stand . . . . . . . . . . . . . . . Socket for electrical accessories Spare parts . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . Steering lock . . . . . . . . . . . . . Stopping . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*3211821en* 3211821en 03/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.
