KTM RC 250 R Owner's Manual
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KTM RC 250 R Owner's Manual

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OWNER'S MANUAL
2014
RC 250 R
Art. no. 3213113en

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Summary of Contents for KTM RC 250 R

  • Page 1 OWNER'S MANUAL 2014 RC 250 R Art. no. 3213113en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 10 TUNING THE CHASSIS ..........27 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 10.1 Adjusting the compression damping of the Symbols used ........... 4 fork ............... 27 Formats used............ 4 10.2 Adjusting the rebound damping of the fork ..27 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 13 WHEELS, TIRES ............52 23 WIRING DIAGRAM ............. 84 23.1 Page 1 of 5 ............ 84 13.1 Removing the front wheel ......52 23.2 Page 2 of 5 ............ 86 13.2 Installing the front wheel ......52 23.3 Page 3 of 5 ............

  • Page 6: Means Of Representation

    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. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 7: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use, but not for offroad use. Info The motorcycle may only be used in closed off areas remote from public road traffic.

  • Page 8: Protective Clothing

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 9: Important Notes

    Spare parts, accessories For your own safety, only use spare parts and accessories approved and/or recommended by KTM. Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (example) L00485-10 Map‑Select switch ( p. 12) Launch‑Control button ( p. 12) Pit‑Limiter button ( p. 12) Tail light switch ( p. 11) Clutch lever ( p. 11) Filler cap Shock absorber compression adjustment, High Speed Shock absorber compression adjustment, Low Speed Fork compression adjustment Quick shifter (...

  • Page 11: View Of Vehicle, Rear Right Side (Example)

    VIEW OF VEHICLE View of vehicle, rear right side (example) L00486-10 Ignition switch ( p. 11) Fork rebound adjustment Fork, spring preload adjustment Indicator lamps ( p. 12) Throttle grip ( p. 11) Hand brake lever ( p. 11) Foot brake lever ( p.

  • Page 12: Serial Numbers

    SERIAL NUMBERS Vehicle identification number The chassis number is located on the right behind the steering head on the frame. L00489-10 Engine number The engine number is stamped on the right side of the engine. L00585-10 Fork part number The fork part number is stamped on the upper side of the fork.

  • Page 13: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. L00464-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake. L00463-10 Throttle grip The throttle grip...

  • Page 14: Map-Select Switch

    CONTROLS Map‑Select switch The Map‑Select switch is fitted on the left side of the handlebar. Possible states MAP 1 – In this position, Mapping 1 is activated. MAP 2 – In this position, Mapping 2 is activated. Two mappings can be stored in the control unit. The Map‑Select switch can be used to change between these two mappings and thus to alter the engine characteristics.
  • Page 15 CONTROLS The red warning lamp lights up – The coolant temperature has reached a critical value. The shift warning light flashes yellow – The set shift speed will soon be reached. The shift warning light flashes red – The set shift speed has been reached.

  • Page 16: Combination Instrument 1/2

    CONTROLS 6.11 Combination instrument 1/2 3 -1 Overview The RPM shift light Setting range:5,000~16,000 RPM. Setting unit:100 RPM. Pre-shift light Tachometer (16,000 RPM) Setting range: Display range: 0~16,000 RPM. -500~-5,000 RPM. Setting unit: 100 RPM. Pre-shift light Shift light (Yellow light) (Red light) ver heat warning light Setting range: 6...

  • Page 18: Combination Instrument 2/2

    CONTROLS 6.12 Combination instrument 2/2 Press the Select button to enter the signal Press the Adjust button to change the setting input setting screen. digit. EX. Now the piston setting is changed from Setting range: -500~-5,000 RPM. 1 P (Piston) to 4 P (Pistons). Setting unit: 100 RPM.

  • Page 19: Opening The Filler Cap

    CONTROLS 6.13 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 20: Idle Speed Adjusting Screw

    CONTROLS 6.15 Idle speed adjusting screw The idle speed adjusting screw is located on the throttle valve body on the left side. Turning the screw clockwise decreases the idle speed. Turning the screw counterclockwise increases the idle speed. L00577-10 6.16 Shift lever The shift lever is mounted on the left of the engine.

  • Page 21: Preparing For Use

    PREPARING FOR USE Advice on first use Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk.

  • Page 22: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 23: Transport

    – 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.
  • Page 24 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 17) – Fill the fuel tank with fuel up to the lower edge of the fuel filler neck. Total fuel tank 10.5 l Super unleaded (ROZ 100) ( p.

  • Page 25: Service Schedule

    SERVICE SCHEDULE Service schedule 13,500 rpm Every 1,500 km (930 mi) Every 1,000 km (620 mi) Every 500 km (310 mi) Every 250 km (155 mi) ● ● ● Check the brake discs. ( p. 45) ● ● ● ● Check the front brake linings.

  • Page 26: Service Schedule 14,000 Rpm

    SERVICE SCHEDULE Every 4,000 km (2,485 mi) Every 3,000 km (1,864 mi) Every 2,000 km (1,240 mi) ● Change the shift lever bearing and foot brake lever bearing. ● Change the radiator hoses. ● Change the rubber dampers. ● Change the hose of the front brake fluid reservoir. ●...

  • Page 27: Maintenance Work (As An Additional Order) 14,000 Rpm

    SERVICE SCHEDULE Every 1,500 km (930 mi) Every 1,000 km (620 mi) Every 500 km (310 mi) Every 250 km (155 mi) ● ● ● Clean the air filter. p. 36) ● Change the air filter. ● Check the air filter box lid gasket. ●...
  • Page 28 SERVICE SCHEDULE Every 4,000 km (2,485 mi) Every 2,000 km (1,240 mi) Every 1,500 km (930 mi) Every 1,000 km (620 mi) ● Change the valves, valve springs, valve spring seats, valve stem seal, and valve spring retainer. ● Change the cam lever. ●...

  • Page 29: Tuning The Chassis

    TUNING THE CHASSIS 10.1 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when the load shifts very fast.

  • Page 30: Fork Offset

    TUNING THE CHASSIS Info Turn clockwise to increase spring preload; turn counterclockwise to reduce spring preload. Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work. Basically, however, you should set the rebound damping higher when the higher spring preload is higher.

  • Page 31: Compression Damping Of The Shock Absorber

    TUNING THE CHASSIS – Loosen screw L00590-11 – Turn the steering stem insert by 180°. L00591-13 – Tighten screw Guideline Screw, steering head pipe 15 Nm Thread greased clamp (11.1 lbf ft) L00590-11 – Tighten the steering stem screw Guideline Screw, steering stem M12x1 25 Nm...

  • Page 32: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 33: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Standard 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- L00490-10 ing.

  • Page 34: Adjusting The Steering Damper

    TUNING THE CHASSIS 10.12 Adjusting the steering damper Info The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load. In contrast to other damping elements, the steering damper is adjusted with the damping element open. –...
  • Page 35 TUNING THE CHASSIS – Loosen screws on the lower triple clamp. – Loosen screw on the upper triple clamp. – Loosen screws on the handlebar stub. Info Loosen the screws far enough to prevent damage to the lacquer when the fork legs are moved.

  • Page 36: Adjusting The Vehicle Level At The Rear

    TUNING THE CHASSIS 10.15 Adjusting the vehicle level at the rear Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –...

  • Page 37: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the rear of the motorcycle with lifting gear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Stand the motorcycle upright, align the lifting gear to the link fork and the adapters, and raise the motorcycle.

  • Page 38: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11.5 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. –...

  • Page 39: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Thoroughly spray the dry air filter with filter oil. Air filter oil ( p. 95) – Leave the filter oil on the filter for 20 minutes. – Clean the air filter box. – Check the distribution of the filter oil. »...

  • Page 40: Removing The Engine Cowl

    SERVICE WORK ON THE CHASSIS 11.8 Removing the engine cowl – Unlock quick releases – Take off engine cowl L00547-10 11.9 Installing the engine cowl – Position engine cowl – Lock quick releases L00547-11 11.10 Removing the front fairing Preparatory work –...

  • Page 41: Installing The Front Fairing

    SERVICE WORK ON THE CHASSIS 11.11 Installing the front fairing Main work – Position front fairing – Mount cotter pins L00515-11 Finishing work – Install the engine cowl. ( p. 38) 11.12 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. –...

  • Page 42: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Raise the fuel tank. – Disconnect connector of the fuel pump. – Take off the fuel tank. L00534-10 11.13 Installing the fuel tank 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.

  • Page 43: Checking The Fuel Overflow Reservoir

    SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining chassis screws 12 Nm (8.9 lbf ft) L00516-11 11.14 Checking the fuel overflow reservoir – Check the fluid level in the fuel overflow reservoir » If there is fluid in the fuel overflow reservoir: –...

  • Page 44: Checking The Coolant Overflow Reservoir

    SERVICE WORK ON THE CHASSIS 11.16 Checking the coolant overflow reservoir – Check the fluid level in the coolant overflow reservoir » If there is fluid in the coolant overflow reservoir: – Empty the coolant overflow reservoir. ( p. 42) L00510-11 11.17 Emptying the coolant overflow reservoir...

  • Page 45: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 95) – After drying, apply chain spray. Chain lube for road use ( p.

  • Page 46: Checking The Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Turn adjusting screws on the left and right so that distance is identical on the left and right. The rear wheel is then correctly aligned. –...

  • Page 47: Brake System

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

  • Page 48: Adding Front Brake Fluid

    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.

  • Page 49: Changing The Front Brake Linings

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

  • Page 50: Checking Rear Brake Fluid Level

    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.

  • Page 51: Adding Rear Brake Fluid

    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.

  • Page 52: Checking The Rear Brake Linings

    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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 53 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 54: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the rear of the motorcycle with lifting gear. ( p. 35) – Raise the front of the motorcycle with lifting gear. ( p. 35) Main work – Loosen screws –...

  • Page 55: Installing The Rear Wheel

    WHEELS, TIRES – Remove wheel spindle L00536-10 – Push the rear wheel as far forward as possible and then remove the chain from the rear sprocket. Info Protect the motorcycle and attachments against damage by covering them. Warning Danger of accidents Reduced braking efficiency due to damaged brake discs.

  • Page 56: Checking The Rear Hub Rubber Dampers

    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.

  • Page 57: Checking The Tire Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufac- ture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years. »...

  • Page 58: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery 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. –...

  • Page 59: Changing The Main Fuse

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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.
  • Page 60 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the engine cowl. ( p. 38) – Remove the front fairing. ( p. 38) Main work – Take off protection cap – Remove the faulty main fuse –...

  • Page 61: Data Recording

    With a CAN bus logger, the messages can be recorded and read out at a later time. KTM recommends using the KTM PowerParts CAN Bus Logger. Alternatively, a data recording system from 2D or GET can be used.

  • Page 62: Can Matrix

    DATA RECORDING 15.5 CAN matrix L00569-01...

  • Page 63: Cooling System

    COOLING SYSTEM 16.1 Cooling system The water pump with a 3D water pump impeller in the engine ensures forced cir- culation of the coolant. The heat exchanger enables faster warming of the engine oil at the start of a journey and better heat dissipation for the engine oil during the journey. The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap .

  • Page 64: Refilling With Coolant

    COOLING SYSTEM Main work – Position the motorcycle upright. – Place a suitable container under the engine. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount screw with a new seal ring and tighten. Guideline Remaining engine screws 6 Nm (4.4 lbf ft)

  • Page 65: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 66: Adjusting The Idle Speed

    TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine until it is warm. – Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,900… 3,100 rpm Info Turning the screw clockwise decreases the idle speed. Turning the screw counterclockwise increases the idle speed.

  • Page 67: Positioning The Quick Shifter

    TUNING THE ENGINE 17.6 Positioning the quick shifter Preparatory work – Remove the engine cowl. ( p. 38) Main work – Loosen nuts – Remove screws L00652-10 – Turn heim joints into the desired position on both sides. Info The screw must be screwed in by at least 6 full turns. The two heim joints must be parallel to each other.

  • Page 68: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Info The engine oil level can be checked on a cold or hot engine. Preparatory work – Stand the motorcycle upright on a horizontal surface. – Remove the engine cowl. ( p.
  • Page 69 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surfaces. – Mount and tighten the screw plug with the oil screen and the O-rings. Guideline Plug, oil screen 40 Nm...

  • Page 70: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 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 ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 71 SERVICE WORK ON THE ENGINE – Remove the cooling air guide, radiator hoses, and radiator. – Remove the main silencer, connecting pipe, and exhaust pipe. – Remove the sprocket. – Remove the shift linkage. – Disconnect the ground wire and all plug-in connections. –...

  • Page 72: Installing The Engine

    SERVICE WORK ON THE ENGINE – Take off chain link and the lower left engine spacer – Take off the upper left engine spacer – Lower the engine with the scissors stand. L00660-11 18.5 Installing the engine Main work – Position the adjustable engine spacers to create sufficient space for the engine.
  • Page 73 SERVICE WORK ON THE ENGINE – Pull out the upper engine bracket screw slightly and tighten the upper adjustable engine spacer Guideline Screw, engine spacer M16x1 10 Nm Thread greased (7.4 lbf ft) – Mount the upper engine bracket screw L00665-10 –...
  • Page 74 SERVICE WORK ON THE ENGINE – Mount the exhaust pipe, connecting pipe, and main silencer. – Mount the radiator, radiator hoses, and cooling air guide. – Refill with coolant. p. 62) – Mount the battery holder. – Connect the battery. –...

  • Page 75: Ems Components

    CD-ROM. Various parameters can be adjusted using the software. Info KTM would like to emphasize that incorrect parameter settings can cause dam- age to the vehicle and engine. Explicit instructions on how to install and use the software are also contained on the CD-ROM.

  • Page 76: Adjusting The Gear Position Sensor

    EMS COMPONENTS L00566-10 – Transfer the sensor value reading plus 2 bits into the TPS_MIN field. – Fully open the throttle valve. Read out the sensor value in the REAL_TIME_TPS field and transfer the maximum value reading minus 2 bits into the TPS_MAX field. –...
  • Page 77 EMS COMPONENTS L00567-10 – Select Start Calibration Read. The current sensor value is displayed in [bit] in the REAL_TIME_GEAR field. – Release screws and change the position of the gear position sensor until the specified value is reached. Guideline REAL_TIME_GEAR 51 bit –...

  • Page 78: Cleaning, Care

    CLEANING, CARE 20.1 Cleaning the motorcycle 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.

  • Page 79: Storage

    Guideline Storage temperature of vehicle 0… 35 °C (32… 95 °F) Info KTM recommends raising the motorcycle. – Raise the rear of the motorcycle with lifting gear. ( p. 35) – Raise the front of the motorcycle with lifting gear. ( p.

  • Page 80: Technical Data

    TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine with balancer shaft, water-cooled Displacement 249.5 cm³ (15.225 cu in) Stroke 48.5 mm (1.909 in) Hole 81 mm (3.19 in) Compression ratio 14.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - valve stem diameter Intake 34.5 mm (1.358 in) Exhaust...
  • Page 81 TECHNICAL DATA Loctite ® 243™ Screw, bearing shell retaining bracket 6 Nm (4.4 lbf ft) Screw, gear position sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, intake flange 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite ®...

  • Page 82: Capacities

    TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 0.75 l (0.79 qt.) Engine oil (SAE 0W/40) ( p. 94) 22.3.2 Coolant Coolant 0.7 l (0.7 qt.) Distilled water 22.3.3 Fuel Total fuel tank capacity, 10.5 l (2.77 US gal) Super unleaded (ROZ 100) ( p.

  • Page 83: Tires

    95/75 R 17 M/C TL 115/75 R 17 M/C TL Dunlop Moto3 M Slick Dunlop Moto3 M Slick Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 07.18.2M.01 WP Suspension Up Side Down 3548...
  • Page 84 TECHNICAL DATA Screw, axle clamp 12 Nm (8.9 lbf ft) Thread greased Screw, bottom triple clamp 12 Nm (8.9 lbf ft) Thread greased Screw, footrest 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, footrest bracket 20 Nm (14.8 lbf ft) Loctite ®...

  • Page 86: Wiring Diagram

    WIRING DIAGRAM 23.1 Page 1 of 5 -X90 V_BAT_SW ALARMS CW/2 -X53 V_BAT_SW CW/2 -X91 V_BAT_SW PIT/LAUNCH light CW/2 +ML -X97 splice /2.B4 -X69 GND_SENS VREF2 /3.B5 P_FB CY/3 -X65 GND_SENS V_BAT_SW CU/4 -X82 Tacho GND_BAT -X78 V_BAT_SW T_WD_+ T_WD_- AO/26 +ML -X98 splice...
  • Page 87 WIRING DIAGRAM Components: Engine control unit T_DASH Temperature sensor for dashboard ALARM Red indicator lamp Yellow indicator lamp PIT/LC LIGHT Green indicator lamp P_FB Pressure front brake Wheel speed front dash Dashboard connector SUS_F Suspension sensor front CAN-bus interface connector Interface Interface connection for ECU communication...
  • Page 88 WIRING DIAGRAM 23.2 Page 2 of 5 -X93 GEARCUT CR/1 -X94 GEARCUT_SW /3.B3 CR/1 -X57 MAPCHANGE GND_SENS /1.B6 V_BAT_SW /1.B3 Light /5.B4 CN/9 V_BAT_F /3.B6 M_SW /5.B3 AZ/4 -X89 V_BAT GND_SENS /1.B6 DA/4 L00571-01...
  • Page 89 WIRING DIAGRAM Components: QS_SW Quick shifter switch MAP/LIGHT_SW Map-select and rear light switch (left handlebar) MAIN_SW Main switch (right handlebar) PIT_LC_SW Pit-limiter / launch-control switch (left handlebar)
  • Page 90 WIRING DIAGRAM 23.3 Page 3 of 5 -X39 GND_SENS /5.B1 TENG AX/2 -X55 GEARCUT_SW /2.B4 GND_SENS +ML -X100 EL/2 splice /4.B3 -X62 VREF2 /5.B3 GND_SENS GEAR CU/4 +ML -X101 splice V_BAT GND_BAT /1.B3 EZ/3 /1.B6 /1.B5 209,210,211,295 GND_BAT /5.B5 -X113 /2.B5 195,196 V_BAT_F...
  • Page 91 WIRING DIAGRAM Components: TENG Engine temperature sensor GEARCUT Quick shifter sensor GEAR Gear position sensor Rectifier/Regulator Voltage regulator ‑XE Ground FUSEBOX Fusebox BATT Battery...
  • Page 92 WIRING DIAGRAM 23.4 Page 4 of 5 -X38 GND_SENS /3.B3 TAIR CM/2 -X59 POIL GB/2 -X35 VREF1 TPS1 GND_SENS AM/3 -X18 INJ1 V_BAT_SW /5.B3 DQ/2 -X19 INJ2 V_BAT_SW /5.B3 DQ/2 -X23 COIL_CMD CR/1 -X24 V_BAT_SW /5.B3 CR/1 -X31 STEPPER_A STEPPER_B STEPPER_C STEPPER_D L00573-01...
  • Page 93 WIRING DIAGRAM Components: T_AIR Air temperature sensor POIL Oil pressure sensor Throttle position sensor INJ_L Injector low INJ_H Injector high COIL_CMD Ignition coil command COIL_+ Ignition coil voltage supply Stepper Motor Stepper motor bypass at the throttle valve...
  • Page 94 WIRING DIAGRAM 23.5 Page 5 of 5 /1.B6 /3.B2 +ML -X61 -X70 GND_SENS splice VREF2 P_RB CY/3 -X72 GND_SENS VREF2 SUS_R +ML -X63 CY/3 splice /3.B4 M_SW /2.B5 GND_BAT V_BAT_F /3.B6 197,198,199,219 V_BAT_SW EB/4 /4.B5 /4.B5 /4.B6 +ML -X41 -X80 splice GND_BAT Light...
  • Page 95 WIRING DIAGRAM Components: P_RB Pressure rear brake sensor SUS_R Suspension rear sensor main_relais Power relay light Rear light Laptrigger 12V power supply for laptimer Wheel speed rear Fuelpump Fuel pump PickUp Pick-up sensor...
  • Page 96 SUBSTANCES Brake fluid DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standards and that possesses the necessary properties. Recommended supplier Motorex ® – Brake Fluid DOT 5.1 Engine oil (SAE 0W/40) Standard/classification – JASO T903 MA ( p.
  • Page 97 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Twin Air Dirt Bio Remover Air filter oil Recommended supplier Motorex ® – Air Filter Oil Spray 655 Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex...
  • Page 98 STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.
  • Page 99 INDEX expansion sensors ......59 INDEX Accessories ........7 Engine Air filter installing .
  • Page 100 INDEX Idle speed adjusting screw ......18 Spare parts ........7 Ignition switch .
  • Page 101 *3213113en* 3213113en 11/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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