KTM 390 DUKE 2017 Owner's Manual
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KTM 390 DUKE 2017 Owner's Manual

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OWNER'S MANUAL
2017
390 Duke
Art. no. 3213566en

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Summary of Contents for KTM 390 DUKE 2017

  • Page 1 OWNER'S MANUAL 2017 390 Duke Art. no. 3213566en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 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 assur- ance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Service ........... 24 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 9 Figures ........... 24 Symbols used ........9 Customer service......24 Formats used........10 VIEW OF VEHICLE ........26 SAFETY ADVICE.......... 11 View of vehicle, front left (example) ... 26 Use definition........
  • Page 6 Quick Selector 2 display ....62 6.10 Closing the filler cap ......42 7.17 Menu..........63 6.11 Seat lock......... 43 7.17.1 KTM MY RIDE (optional) ....63 6.12 Tool set........... 43 7.17.2 Info ..........64 6.13 Grab handles ........44 7.17.3 Motorcycle ........
  • Page 7 TABLE OF CONTENTS 7.17.18 Shift Light ........78 10 SERVICE SCHEDULE ........ 108 7.17.19 Setting the time and date ..... 78 10.1 Additional information ....108 7.17.20 DRL ........... 81 10.2 Required work ....... 108 7.17.21 Distance ........82 10.3 Recommended work .......
  • Page 8 TABLE OF CONTENTS 12.10 Checking for chain dirt 13.9 Checking the rear brake fluid accumulation......... 124 level ..........148 12.11 Cleaning the chain ......124 13.10 Adding rear brake fluid ....149 12.12 Checking the chain tension ..... 126 13.11 Checking the rear brake linings ..152 12.13 Adjusting the chain tension.....
  • Page 9 TABLE OF CONTENTS 15.10 Diagnostics connector ....184 19.2 Checks and maintenance steps for winter operation......209 15.11 USB diagnostics plug ..... 185 16 COOLING SYSTEM ........186 20 STORAGE ..........211 20.1 Storage ......... 211 16.1 Cooling system ......186 20.2 Preparing for use after storage..
  • Page 10 TABLE OF CONTENTS 25 AUXILIARY SUBSTANCES ......240 26 STANDARDS ..........242 27 INDEX OF SPECIAL TERMS ....... 243 28 LIST OF ABBREVIATIONS......244 29 LIST OF SYMBOLS........245 29.1 Red symbols........245 29.2 Yellow and orange symbols....245 29.3 Green and blue symbols....

  • Page 11: 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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 12: Formats Used

    1 MEANS OF REPRESENTATION Indicates the end of an activity including potential reworking. Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name ® Indicates a protected name. Brand™ Indicates a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.

  • Page 13: Safety Advice

    2 SAFETY ADVICE 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.

  • Page 14: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
  • Page 15 2 SAFETY ADVICE...

  • Page 16: Overview Of Labels

    2 SAFETY ADVICE Overview of labels V00697-10...
  • Page 17 2 SAFETY ADVICE Type label for Canada Information on emissions control Information on preparations for use Type label for USA Information on noise emissions Type label for Canada F00992-01...
  • Page 18 2 SAFETY ADVICE Information on emissions control F00994-01 Information on preparations for use F00491-01...

  • Page 19: Consumer Rights

    Information on noise emissions F00993-01 Consumer rights Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553 www.ktmusa.com KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7...

  • Page 20: Operating Noise Warning

    Otherwise, the owner may become subject to penalties under the applicable ordinances. Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

  • Page 21: Tampering Warning

    However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington,...

  • Page 22: Safe Operation

    An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 23: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.13 Work rules Special tools are necessary for certain tasks.

  • Page 24: Environment

    Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

  • Page 25: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void.

  • Page 26: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
  • Page 27 3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 28: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V00696-10...
  • Page 29 4 VIEW OF VEHICLE Combination instrument Clutch lever ( p. 33) Front rider's seat Passenger seat Grab handles ( p. 44) Seat lock ( p. 43) Shift lever ( p. 45) Side stand ( p. 46) Engine number ( p. 31)

  • Page 30: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) V00695-10...
  • Page 31 4 VIEW OF VEHICLE Tool set ( p. 43) Light switch ( p. 35) Menu switch ( p. 36) Turn signal switch ( p. 36) Horn button ( p. 37) Emergency OFF switch ( p. 37) Electric starter button ( p.

  • Page 32: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 0 0 1 402408-10 Type label The type label USA is located on the top frame on the right. 402478-10...

  • Page 33: Engine Number

    5 SERIAL NUMBERS The type label Canada is located on the bottom frame on the left. 402477-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 402486-10...

  • Page 34: Key Number

    5 SERIAL NUMBERS Key number The 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. 402245-10...

  • Page 35: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. F00783-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever. F00784-10...

  • Page 36: Throttle Grip

    6 CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. F00784-11 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar.

  • Page 37: Light Switch

    6 CONTROLS Overview of the left combination switch Light switch ( p. 35) Menu switch ( p. 36) Turn signal switch ( p. 36) Horn button ( p. 37) F00785-10 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on –...

  • Page 38: Menu Switch

    6 CONTROLS 6.4.3 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the display on the combina- tion instrument. Button is the UP button. Button is the DOWN button. Button is the SET button.

  • Page 39: Horn Button

    6 CONTROLS 6.4.5 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this posi- • Horn button tion. F00787-12 Switches on the right side of the handlebar 6.5.1 Emergency OFF switch The emergency OFF switch...

  • Page 40: Electric Starter Button

    6 CONTROLS 6.5.2 Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the elec- • Electric starter button tric starter is actuated. F00789-10 Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp.

  • Page 41: Locking The Steering

    6 CONTROLS Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar all the way to the left. –...

  • Page 42: Unlocking The Steering

    6 CONTROLS Unlocking the steering – Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove the key. You can now steer the bike again. 400731-01 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 43 6 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 44: Closing The Filler Cap

    6 CONTROLS 6.10 Closing the filler cap Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. – Check the filler cap is locked correctly after clos- ing. – Change your clothing in case of fuel spills on them. –...

  • Page 45: Seat Lock

    6 CONTROLS 6.11 Seat lock The seat lock is located to the left of the seat. The seat lock can be unlocked using the ignition key. F00790-10 6.12 Tool set The tool set is located under the passenger seat. F00729-10...

  • Page 46: Grab Handles

    6 CONTROLS 6.13 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. F00791-10 6.14 Passenger footrests The passenger footrests can be folded in and out. Possible states Passenger footrests folded up –...

  • Page 47: Shift Lever

    6 CONTROLS 6.15 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11...

  • Page 48: Foot Brake Lever

    6 CONTROLS 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10 6.17 Side stand The side stand is on the left side of the vehicle. The side stand is used to park the motorcycle.
  • Page 49 6 CONTROLS Side stand folded in – This position is mandatory for all trips. • The safety start system is inactive.

  • Page 50: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument The combination instrument is attached in front of the handlebar. The combination instrument is divided into two function areas. indicator lamps ( p. 52) Display 402800-10 Activation and test Activation The combination instrument is activated when the ignition is switched on.

  • Page 51: Day-Night Mode

    7 COMBINATION INSTRUMENT Day-Night mode Day mode is shown in a bright color. 402803-01 Night mode is shown in a dark color. Info The light sensor in the combination instrument measures the brightness of the environment and automatically switches the display to day or night mode. The display is brightened, darkened or switched to the other mode depending on the brightness measured by the light sensor.

  • Page 52: Warning Notes

    7 COMBINATION INSTRUMENT Warning notes Warning notes appear on the top and/or bottom edge of the dis- play, these are marked yellow or red depending on their relevance. Yellow warning notes indicate errors or information which requires prompt intervention or an adjustment to the riding style. Red warning notes indicate errors or information which requires immediate intervention.
  • Page 53 7 COMBINATION INSTRUMENT...

  • Page 54: Indicator Lamps

    7 COMBINATION INSTRUMENT Indicator lamps F00900-01...
  • Page 55 7 COMBINATION INSTRUMENT The indicator lamps offer additional information about the operating state of the motorcycle. When the ignition is switched on, all indicator lamps light up briefly. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on.

  • Page 56: Display

    7 COMBINATION INSTRUMENT Display F00877-10...
  • Page 57 7 COMBINATION INSTRUMENT Speed ( p. 56) Shift warning light ( p. 57) The shift warning light is integrated in the tachometer display. Gear display Unit for the speed display Speed ( p. 58) Unit for the speedometer ODO display ( p.

  • Page 58: Speed

    7 COMBINATION INSTRUMENT Speed The speed is measured in revolutions per minute. F00878-12...

  • Page 59: Shift Warning Light

    7 COMBINATION INSTRUMENT Shift warning light The shift warning light is integrated in the tachometer display. In the Shift Light menu, the engine speed for the shift warning light can be set. The shift warning light is always active during the running-in phase (up to 1,000 km / 621 mi).

  • Page 60: Speed

    7 COMBINATION INSTRUMENT RPM2 shift warning flashes light Speed Speed is shown in kilometers per hour km/h or in miles per hour mph. 402806-10...

  • Page 61: Odo Display

    7 COMBINATION INSTRUMENT 7.10 ODO display The total distance covered ODO is shown in area of the display. Info This value is retained, even if the battery is disconnected from the vehicle or the fuse blows. 402806-12 7.11 Coolant temperature indicator The coolant temperature indicator consists of bars.

  • Page 62: Fuel Level Display

    7 COMBINATION INSTRUMENT 7.12 Fuel level display The fuel tank contents are shown in area of the display. The fuel level indicator consists of bars. The more bars are lit, the more fuel is in the fuel tank. Info If the fuel level is getting low, the last segment flashes red and the following warning note also appears LOW FUEL.

  • Page 63: Time

    7 COMBINATION INSTRUMENT 7.13 Time The time is shown in area of the display. The time is displayed in 24 hour format in all languages except for EN-US. The time is displayed in 12 hour format if the language is set to EN-US.

  • Page 64: Quick Selector 1 Display

    7 COMBINATION INSTRUMENT 7.15 Quick Selector 1 display When the menu is closed, the Quick Selector 1 menu is opened by pressing the UP button. Press the BACK button to close Quick Selector 1. Info The Quick Selector 1 can be configured in the Quick Selec- tor 1 menu.

  • Page 65: Menu

    – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. In KTM MY RIDE a suitable cellphone can be paired with the com- bination instrument via Bluetooth ® F00804-01...

  • Page 66: Info

    7 COMBINATION INSTRUMENT Info Not every cellphone is suitable for pairing with the combi- nation instrument. The standard Bluetooth ® 2.1 must be supported. 7.17.2 Info – Press the SET button when the menu is closed. – Press the UP or DOWN button until Info is marked. Press the SET button to open the menu.

  • Page 67: Motorcycle

    7 COMBINATION INSTRUMENT 7.17.3 Motorcycle – Press the SET button when the menu is closed. – Press the UP or DOWN button until Motorcycle is marked. Press the SET button to open the menu. The vehicle drive mode can be configured in Motorcycle. F00804-03 7.17.4 Settings...

  • Page 68: Preferences

    – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. F00842-01 – Press the UP or DOWN button until Pairing is marked. Press...
  • Page 69 7 COMBINATION INSTRUMENT – Press the UP or DOWN button until Pairing is marked. Press the SET button to pair a suitable cellphone with the combina- tion instrument via Bluetooth ® – Confirmation of the Passkey successfully completes the pair- ing.

  • Page 70: Audio (Optional)

    – Press the SET button when the menu is closed. – Press the UP or DOWN button until KTM MY RIDE is marked. Press the SET button to open the menu. F00837-01 Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity.
  • Page 71 7 COMBINATION INSTRUMENT Info The audio function can be added to Quick Selector 1 or Quick Selector 2 for easier operation.

  • Page 72: Telephony (Optional)

    7 COMBINATION INSTRUMENT 7.17.8 Telephony (optional) Condition • Function KTM MY RIDE activated (optional). • Function Bluetooth ® activated. • The Bluetooth ® function should also be activated in the device to be paired. • Headset linked with appropriate cellphone.

  • Page 73: General Info

    7 COMBINATION INSTRUMENT 7.17.9 General Info – Press the SET button when the menu is closed. – Press the UP or DOWN button until Info is marked. Press the SET button to open the menu. – Press the UP or DOWN button until General Info is marked. Press the SET button to open the menu.

  • Page 74: Trip 2

    7 COMBINATION INSTRUMENT Fuel Range indicates the possible distance you can cover with the fuel reserve. Press and All entries in the Trip 1 menu are reset. hold the SET button for 3-5 seconds. 7.17.11 Trip 2 – Press the SET button when the menu is closed. –...

  • Page 75: Warning

    7 COMBINATION INSTRUMENT Press and All entries in the Trip 2 menu are reset. hold the SET button for 3-5 seconds. 7.17.12 Warning Condition • Message or warning is present. – Press the SET button when the menu is closed. –...

  • Page 76: Abs

    7 COMBINATION INSTRUMENT 7.17.13 ABS Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Motorcycle is marked. Press the SET button to open the menu. –...

  • Page 77: Favourites

    7 COMBINATION INSTRUMENT Press and Activation of the different ABS modes. hold the SET button for 3-5 seconds. 7.17.14 Favourites Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Settings is marked. Press the SET button to open the menu.

  • Page 78: Quick Selector 1

    7 COMBINATION INSTRUMENT 7.17.15 Quick Selector 1 Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Settings is marked. Press the SET button to open the menu. –...

  • Page 79: Bluetooth

    F00818-01 off. Info The Bluetooth ® function can only be used in conjunction with KTM MY RIDE (optional). When the Bluetooth ® function is switched on, the Blue- tooth ® symbol appears in the display of the combination...

  • Page 80: Shift Light

    7 COMBINATION INSTRUMENT 7.17.18 Shift Light Condition • The motorcycle is stationary. • ODO > 1000 km (621 mi). – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu.
  • Page 81 7 COMBINATION INSTRUMENT – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences appears. Press the SET button to open the menu. – Press the UP or DOWN button until Clock/Date is marked. Press the SET button to open the menu.
  • Page 82 7 COMBINATION INSTRUMENT Setting the date – Press the UP or DOWN button until the date is marked. – Press the SET button. The day flashes and is underlined. – Press the UP or DOWN button until the current day is set. –...

  • Page 83: Drl

    7 COMBINATION INSTRUMENT 7.17.20 DRL Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. Warning Danger of accidents When visibility is poor, the day- time running light is not a substitute for the low beam.

  • Page 84: Distance

    7 COMBINATION INSTRUMENT – Press the UP or DOWN button until DRL is marked. Press the SET button to open the menu. – Activate the menu item using the UP or DOWN button. – Press the SET button to switch the daytime running light on or off.

  • Page 85: Temp

    7 COMBINATION INSTRUMENT 7.17.22 Temp Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. –...

  • Page 86: Language

    7 COMBINATION INSTRUMENT 7.17.24 Language Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until Preferences is marked. Press the SET button to open the menu. –...

  • Page 87: Extra Functions

    Use the UP or DOWN button to navigate through the extra func- F00831-01 tions. The optional extra functions are listed in Extra Functions. Info The current KTM PowerParts and the available software for your vehicle can be found on the KTM website.

  • Page 88: Preparing For Use

    Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel. Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index.
  • Page 89 When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 90: Running In The Engine

    8 PREPARING FOR USE Running in the engine – During the running-in phase, do not exceed the specified engine speed. Guideline Maximum engine speed During the first: 1,000 km (620 mi) 7,500 rpm Info During the running-in phase, the shift warning light is set to a specified value and cannot be changed. –...
  • Page 91 8 PREPARING FOR USE Warning Danger of accidents Improper mounting of cases or the tank rucksack impairs the handling characteris- tic. – Mount and secure cases and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents The luggage system will be damaged if it is overloaded. –...
  • Page 92 8 PREPARING FOR USE – If you carry any 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 overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 355 kg (783 lb.)

  • Page 93: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.

  • Page 94: Starting

    9 RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing.
  • Page 95 9 RIDING INSTRUCTIONS – Unlock the steering. ( p. 40) – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the posi- tion After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 96: Starting Off

    9 RIDING INSTRUCTIONS Info Do not press the electric starter button until the combi- nation instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

  • Page 97: Shifting, Riding

    9 RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – Adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
  • Page 98 9 RIDING INSTRUCTIONS Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. – Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot rest and holds on to the rider or the grab handles. –...
  • Page 99 Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an autho- rized KTM workshop.
  • Page 100 9 RIDING INSTRUCTIONS – Shift into a higher gear when conditions allow (incline, road situation, etc.). – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info You can see the positions of the 6 forward gears in the figure.
  • Page 101 Contact an authorized KTM workshop. – If the malfunction indicator lamp lights up during a trip, please contact an authorized KTM workshop as soon as possi- ble. – If the general warning lamp lights up during a trip, an oper-...

  • Page 102: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.
  • Page 103 9 RIDING INSTRUCTIONS Warning Danger of accidents Higher total weight increases the stopping distance. – Take the longer stopping distance into account when carrying a passenger or luggage with you. Warning Danger of accidents Salt on the roads impairs the brake system. –...

  • Page 104: Stopping, Parking

    9 RIDING INSTRUCTIONS Warning Danger of accidents The rear wheel can lock due to the engine braking effect. – Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground. Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. –...
  • Page 105 9 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down. –...

  • Page 106: Transport

    9 RIDING INSTRUCTIONS Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine with the ignition key – the emergency OFF switch is intended for emergencies only.

  • Page 107: Refueling

    9 RIDING INSTRUCTIONS – Switch off the engine and remove the ignition key. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 401448-01 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 108 In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.
  • Page 109 9 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 40) – Fill the fuel tank with fuel up to the lower edge of the fuel filler. Total fuel tank 13.5 l Super unleaded capacity, approx. (3.57 US gal) (ROZ 95/RON 95/PON 91)

  • Page 110: Service Schedule

    15,000 km (9,300 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ● Check that the electrical system is functioning properly. ○...
  • Page 111 10 SERVICE SCHEDULE Every two years Every year every 15,000 km (9,300 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ○ ● ● ● ● Check the tire air pressure. ( p. 166) ○ ● ● ● ●...
  • Page 112 Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Set the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 113: Recommended Work

    10 SERVICE SCHEDULE 10.3 Recommended work Every four years Every year every 30,000 km (18,600 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ● ● Check the swingarm bearing for backlash. ●...

  • Page 114: Tuning The Chassis

    11 TUNING THE CHASSIS 11.1 Adjusting the spring pretension of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behav- ior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring pretension defines the initial status of the spring operation on the shock absorber.

  • Page 115: Adjusting The Shift Lever

    11 TUNING THE CHASSIS 11.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. – Loosen nuts – Adjust the shift lever by turning shift rod Guideline Shift rod adjustment 90 … 102 mm (3.54 … range 4.02 in) Info...
  • Page 116 11 TUNING THE CHASSIS Info After the nuts have been tightened, the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells. – Check the shift lever to ensure it is functioning properly and can move freely.

  • Page 117: Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Mount the supports of the lifting gear. –...

  • Page 118: Lifting The Motorcycle With The Front Lifting Gear

    12 SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the vehicle on side stand – Remove bushings kit. 402029-10 12.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over.
  • Page 119 12 SERVICE WORK ON THE CHASSIS Condition – Remove protection cap F00795-10 – Move the handlebar to the straight-ahead position. Position the lifting gear. Mounting pin (69329965030) Front wheel work stand, large (69329965000) Info Always raise the motorcycle at the rear first. –...

  • Page 120: Taking The Motorcycle From The Front Lifting Gear

    12 SERVICE WORK ON THE CHASSIS 12.4 Taking the motorcycle from the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Main work – Secure the motorcycle against falling over.

  • Page 121: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS – Mount protection cap F00795-10 Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 115) 12.5 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 122 12 SERVICE WORK ON THE CHASSIS Main work – Push dust boots of both fork legs downward. Info The dust boots should remove dust and coarse dirt par- ticles from the fork tubes. Over time, dirt can accumu- late behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

  • Page 123: Removing The Passenger Seat

    12 SERVICE WORK ON THE CHASSIS – Remove the rear of the motorcycle from the lifting gear. p. 115) 12.6 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards.

  • Page 124: Mounting The Passenger Seat

    12 SERVICE WORK ON THE CHASSIS 12.7 Mounting the passenger seat – Attach hooks on the passenger seat to seat mounting on the subframe, and lower it at the rear while pushing for- ward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 125: Mounting The Front Rider's Seat

    12 SERVICE WORK ON THE CHASSIS Main work – Raise the rear of the front rider's seat, pull it towards the rear, and remove it upwards. H01993-01 12.9 Mounting the front rider's seat Main work – Attach the front rider's seat in area and lower at the rear.

  • Page 126: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS 12.10 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 124) 400678-01 12.11 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip.
  • Page 127 12 SERVICE WORK ON THE CHASSIS Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 128: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.12 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 129: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Chain tension 5 … 7 mm (0.2 … 0.28 in) » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 127) – Remove the rear of the motorcycle from the lifting gear. p.
  • Page 130 12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 … 7 mm (0.2 … 0.28 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in...

  • Page 131: Checking The Chain, Rear Sprocket, And Engine Sprocket

    12 SERVICE WORK ON THE CHASSIS Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 115) 12.14 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 132 12 SERVICE WORK ON THE CHASSIS – Shift gear to neutral. – Pull the lower chain section with specified weight Guideline Weight, chain wear measure- 15 kg (33 lb.) ment – Measure distance of 20 chain rollers in the lower chain section.
  • Page 133 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If in area by the chain sliding guard screw is visi- ble from above: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 134: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.15 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting wheel Info Push the hand brake lever forward and turn the adjust- ing wheel.

  • Page 135: Fitting Front Spoiler

    12 SERVICE WORK ON THE CHASSIS – Remove screws – Take off the front spoiler. F00797-10 12.17 Fitting front spoiler – Position the front spoiler. Mount screws but do not tighten yet. F00796-10...
  • Page 136 12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Screw, front spoiler M6x9 9 Nm (6.6 lbf ft) rear – Tighten screws Guideline Screw, front spoiler M6x13 9 Nm (6.6 lbf ft) front F00797-10...

  • Page 137: Brake System

    Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire air pressure. –...
  • Page 138 13 BRAKE SYSTEM Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations. It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.

  • Page 139: Adjusting The Basic Position Of The Hand Brake Lever

    13 BRAKE SYSTEM ditions, for example when making "wheelies" or if the rear wheel spins. This causes the ABS to switch off. To reactivate the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reactivated when the vehicle is switched on again.

  • Page 140: Checking The Brake Discs

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at mul-...

  • Page 141: Checking The Brake Fluid Level Of The Front Brake

    KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 142: Adding Front Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 143 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 144 13 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 145: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 146: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. – Check the brake linings for damage and cracking. »...
  • Page 147 13 BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...

  • Page 148: Adjusting The Free Travel Of The Foot Brake Lever

    13 BRAKE SYSTEM 13.8 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
  • Page 149 13 BRAKE SYSTEM – Detach spring – Release nut and use screw to adjust the specified free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) Info The range of adjustment is limited. –...

  • Page 150: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 151: Adding Rear Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 152 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 153 13 BRAKE SYSTEM Main work Condition The screw cap is locked. – Remove screw and take off the screw cap lock. H01142-10 – Stand the vehicle upright. – Remove screw cap with membrane – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 154: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.
  • Page 155 13 BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »...

  • Page 156: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 115) – Lift the motorcycle with the front lifting gear. ( p. 116) Main work – Remove screws with washers and push the fender slightly to the side.

  • Page 157: Installing The Front Wheel

    14 WHEELS, TIRES Info Do not pull the hand brake lever when the front wheel is removed. 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. –...
  • Page 158 14 WHEELS, TIRES – Clean the thread of the wheel spindle and screw – Clean and grease wheel spindle. Long-life grease ( p. 240) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. –...

  • Page 159: Removing The Rear Wheel

    14 WHEELS, TIRES – Remove the rear of the motorcycle from the lifting gear. p. 115) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 14.3 Removing the rear wheel...
  • Page 160 14 WHEELS, TIRES – Remove screw and pull wheel speed sensor out of the hole. – Remove nut and washer. – Remove chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.

  • Page 161: Installing The Rear Wheel

    14 WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.

  • Page 162: The Brake Linings Are Correctly Positioned

    14 WHEELS, TIRES – Clean the mating surfaces of the brake caliper support and swingarm. – Install the rubber damper and rear sprocket carrier on the rear wheel. – Insert the spacers. – Position the rear wheel. The brake linings are correctly positioned. –...

  • Page 163: Mount And Tighten Screw Guideline

    14 WHEELS, TIRES – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Guideline Mount left and right chain adjusters in the same posi- tion. – Mount nut and washer. – Push the rear wheel forward so that the chain adjusters are in contact with the screws, and tighten nut Guideline In order for the rear wheel to be correctly aligned, the mark-...

  • Page 164: Checking The Rear Hub Rubber Dampers

    14 WHEELS, TIRES – Mount and tighten screw Guideline Screw, chain guard EJOT PT ® 7 Nm (5.2 lbf ft) K60x30 F00865-11 Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 115) – Check the chain tension. ( p.
  • Page 165 14 WHEELS, TIRES Main work – Check bearing » If the bearing is damaged or worn: – Change the bearing. – Check the rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: F00868-10 –...

  • Page 166: Checking The Tire Condition

    Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac- teristic.
  • Page 167 14 WHEELS, TIRES Info The type, condition, and air pressure of the tires all have a major impact on the handling characteristics of the motorcycle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces. – Check the front and rear tires for cuts, run-in objects, and other damage.

  • Page 168: Checking The Tire Air Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-10 years at the latest, regardless of the actual state of wear.
  • Page 169 14 WHEELS, TIRES – Remove the dust cap. – Check tire air pressure when the tires are cold. Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger/full payload Front 2.0 bar (29 psi) 400695-01 Rear 2.2 bar (32 psi)

  • Page 170: Electrical System

    15 ELECTRICAL SYSTEM 15.1 Daytime running light (DRL) Warning Danger of accidents When visibility is poor, the daytime running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visi- bility is significantly impaired due to fog, snow or rain.

  • Page 171: Removing The Battery

    15 ELECTRICAL SYSTEM Control is provided by the brightness sensor in the combination instrument. When visibility conditions are good, the low beam is switched off and the daytime running light is switched on. Info The position light lights up with all types of lighting. 15.2 Removing the battery Warning...
  • Page 172 15 ELECTRICAL SYSTEM Main work – Disconnect negative cable from the battery. F00774-10 – Pull back positive terminal cover – Disconnect positive cable from the battery. – Detach rubber band – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery.

  • Page 173: Installing The Battery

    15 ELECTRICAL SYSTEM 15.3 Installing the battery Main work – Position the battery in the battery holder. Battery (ETZ‑9‑BS) ( p. 225) – Reconnect rubber band – Position positive cable and mount and tighten the screw. – Position positive terminal cover F00775-11 –...

  • Page 174: Recharging The Battery

    15 ELECTRICAL SYSTEM 15.4 Recharging 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 safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 175 15 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging 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, or charging time is exceeded, electrolyte escapes through the safety valves.
  • Page 176 15 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the bat- tery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

  • Page 177: Changing The Abs Fuses

    15 ELECTRICAL SYSTEM Finishing work – Mount the front rider's seat. ( p. 123) – Mount the passenger seat. ( p. 122) – Set the time and date. ( p. 78) 15.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. –...
  • Page 178 15 ELECTRICAL SYSTEM To change the fuse of the ABS hydraulic unit: – Take off the protection cap and remove fuse Info You can recognize a faulty fuse by a burned-out fuse wire Warning F00848-10 Fire hazard Incorrect fuses overload the electrical system.
  • Page 179 15 ELECTRICAL SYSTEM To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. F00848-11 –...

  • Page 180: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM 15.6 Changing the fuses of individual power consumers Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the pas- senger seat. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 181 15 ELECTRICAL SYSTEM Main work – Open fuse box cover – Remove the defective fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 10 A - combination instrument Fuse 3 - 10 A - power relay Fuse 4 - 15 A - ignition coil, fuel pump, start auxiliary relay, horn Fuse 5 - 10 A - radiator fan...
  • Page 182 15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

  • Page 183: Changing The Turn Signal Bulb

    15 ELECTRICAL SYSTEM 15.7 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 184: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM Info Insert catch into recess – Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly. 15.8 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of 0 0 A a light wall and make a mark at the height of the center of the low beam headlight.

  • Page 185: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: –...

  • Page 186: Diagnostics Connector

    15 ELECTRICAL SYSTEM – Set the headlight to marking Guideline The light-dark boundary must lie exactly on lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. 400726-11 15.10 Diagnostics connector Diagnostics connector...

  • Page 187: Usb Diagnostics Plug

    15 ELECTRICAL SYSTEM 15.11 USB diagnostics plug The USB diagnostics plug is located under the combination instrument. Info The USB diagnostics plug is intended for diagnostics pur- poses only and is not suitable for supplying power to exter- nal devices. H01907-10...

  • Page 188: Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .
  • Page 189 16 COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan which is controlled by a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. H01905-10...

  • Page 190: Checking The Antifreeze And Coolant Level

    16 COOLING SYSTEM 16.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 191 16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove cap of the compensating tank. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...
  • Page 192 16 COOLING SYSTEM – Remove radiator cap – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: – Correct the antifreeze in the coolant. –...

  • Page 193: Checking The Coolant Level

    16 COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 194 16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Check the coolant level in compensating tank The coolant level must be between the two markings. » If the coolant level does not match the specified value: –...

  • Page 195: Draining The Coolant

    16 COOLING SYSTEM 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 196: Filling/Bleeding The Cooling System

    16 COOLING SYSTEM Main work – Position the motorcycle upright. – Place a suitable container under the engine. – Remove screw – Remove the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline F00857-10 Screw plug, water...
  • Page 197 16 COOLING SYSTEM Main work – Remove radiator cap F00856-10 – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immedi- ately.
  • Page 198 16 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 199: Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the clutch lever play Note Clutch damage If there is no play on the clutch lever, the clutch will begin to slip. – Check the play in the clutch lever on each occasion before operating the motorcycle. –...

  • Page 200: Adjusting Play In The Clutch Lever

    17 TUNING THE ENGINE 17.2 Adjusting play in the clutch lever – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the clutch level by turning adjusting screw Guideline 1 …...

  • Page 201: Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.

  • Page 202: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    18 SERVICE WORK ON THE ENGINE 18.2 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
  • Page 203 18 SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove oil drain plug with the O-ring. – Remove oil screen with the O-ring. – Remove screw plug with oil screen – Completely drain the engine oil. –...
  • Page 204 18 SERVICE WORK ON THE ENGINE – Remove screws . Remove oil filter cover with the O- ring. – Pull oil filter out of the oil filter housing. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. V00700-10 –...
  • Page 205 18 SERVICE WORK ON THE ENGINE – Remove filler plug and the O-ring from the clutch cover, and fill up with engine oil. Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50) p. 238) – Install and tighten the oil filler plug with O-ring. Danger 401955-12 Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 206: Adding Engine Oil

    18 SERVICE WORK ON THE ENGINE 18.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove the oil filler plug with the O-ring from the clutch 0 0 1 cover and fill up with engine oil.
  • Page 207 18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 208: Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 209 19 CLEANING, CARE – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush. Motorcycle cleaner ( p.
  • Page 210 19 CLEANING, CARE – After cleaning, ride the vehicle a short distance until the engine warms up. Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate.

  • Page 211: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 241) – Oil the ignition/steering lock. Universal oil spray ( p.
  • Page 212 19 CLEANING, CARE – Clean the motorcycle. ( p. 206) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.

  • Page 213: Storage

    20 STORAGE 20.1 Storage Info If you want to garage the motorcycle for a longer period, take the following steps. 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.
  • Page 214 20 STORAGE – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 115) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 215: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Take the motorcycle from the front lifting gear. ( p. 118) – Remove the rear of the motorcycle from the lifting gear. p. 115) – Install the battery. p. 171) – Set the time and date.

  • Page 216: Troubleshooting

    Operating error Carry out the start procedure. p. 92) – Fault in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Engine has too little power Air filter is very dirty Change the air filter. –...
  • Page 217 – Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.
  • Page 218 21 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil too thin (low viscos- Change the engine oil and oil filter and ity) clean the oil screens. p. 200) – Headlight and parking light are Fuse 6 blown Change the fuses of individual power not functioning consumers.

  • Page 219: Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 373 cm³ (22.76 cu in) Stroke 60 mm (2.36 in) Bore 89 mm (3.5 in) Compression ratio 12.6:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 36 mm (1.42 in) Valve diameter, exhaust 29 mm (1.14 in)

  • Page 220: Engine Tightening Torques

    22 TECHNICAL DATA 1st gear 12:32 2nd gear 14:26 3rd gear 19:27 4th gear 21:24 5th gear 23:22 6th gear 25:21 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 230 W Spark plug BOSCHVR5NEU Spark plug electrode gap...
  • Page 221 22 TECHNICAL DATA Screw, ignition pulse generator 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket, stator 8 Nm (5.9 lbf ft) Loctite ® 243™ cable Screw, stator 8 Nm (5.9 lbf ft) Loctite ®...
  • Page 222 22 TECHNICAL DATA Screw, clutch spring 10 Nm (7.4 lbf ft) Screw, engine case M6x35 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, engine case M6x75 12 Nm (8.9 lbf ft) Screw, engine sprocket 12 Nm (8.9 lbf ft) Screw, engine vent plate 10 Nm (7.4 lbf ft) Loctite...
  • Page 223 22 TECHNICAL DATA Screw, shift drum locating 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, starter motor 12 Nm (8.9 lbf ft) Screw, timing chain tensioner 12 Nm (8.9 lbf ft) Screw, timing chain tensioning rail 12 Nm (8.9 lbf ft) Loctite ®...
  • Page 224 22 TECHNICAL DATA Screw, cylinder head 1st stage 30 Nm (22.1 lbf ft) 2nd stage 60 Nm (44.3 lbf ft) Thread is oiled, head flat is greased Screw, rotor 105 Nm (77.4 lbf ft) Loctite ® 243™ Water temperature sensor 14 Nm (10.3 lbf ft) Screw plug, cam lever axis M10x1...

  • Page 225: Capacities

    22 TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50) p. 238) 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 237) 22.3.3 Fuel Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.
  • Page 226 22 TECHNICAL DATA Rear Disc brake with single-piston brake caliper, floating Suspension travel front 142 mm (5.59 in) rear 150 mm (5.91 in) Brake discs - diameter Front 320 mm (12.6 in) rear 230 mm (9.06 in) Brake discs - wear limit front 4.5 mm (0.177 in) rear...

  • Page 227: Electrical System

    22 TECHNICAL DATA Ground clearance, unloaded 175 mm (6.89 in) Dry weight 149 kg (328 lb.) Maximum permissible front axle load 127 kg (280 lb.) Maximum permissible rear axle load 228 kg (503 lb.) Maximum permissible overall weight 355 kg (783 lb.) 22.5 Electrical system Battery...

  • Page 228: Tires

    150/60 R 17 M/C 66H TL Michelin Pilot Street Radial Michelin Pilot Street Radial The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork article number 93301000033...

  • Page 229: Chassis Tightening Torques

    22 TECHNICAL DATA Standard 5 clicks Static sag 14 mm (0.55 in) Riding sag 47 mm (1.85 in) Fitted length 304 mm (11.97 in) 22.9 Chassis tightening torques Screw, chain guard EJOT PT ® K60x30 7 Nm (5.2 lbf ft) Remaining screws, chassis 4 Nm (3 lbf ft) Remaining nuts, chassis...
  • Page 230 22 TECHNICAL DATA Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ABS hose clamp 7 Nm (5.2 lbf ft) Screw, ABS module 10 Nm (7.4 lbf ft) Screw, ABS module retaining 7 Nm (5.2 lbf ft) bracket on frame Screw, air filter box 6 Nm (4.4 lbf ft) Screw, brake fluid reservoir of rear...
  • Page 231 22 TECHNICAL DATA Screw, fuel pump 10 Nm (7.4 lbf ft) Screw, fuel tank holder evaporation 9 Nm (6.6 lbf ft) valve Screw, fuel tank trim 5 Nm (3.7 lbf ft) Screw, fuel tank trim 7 Nm (5.2 lbf ft) Screw, headlight 8 Nm (5.9 lbf ft) Screw, ignition coil...
  • Page 232 22 TECHNICAL DATA Screw, rollover sensor 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, shift lever linkage 11 Nm (8.1 lbf ft) Loctite ® 243™ Screw, wheel speed sensor holder 8 Nm (5.9 lbf ft) Nut, rear sprocket 27 Nm (19.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis...
  • Page 233 22 TECHNICAL DATA Screw, horn 12 Nm (8.9 lbf ft) Screw, main silencer 23 Nm (17 lbf ft) Screw, passenger footrest bracket 22 Nm (16.2 lbf ft) Loctite ® 243™ Screw, rear brake disc 21 Nm (15.5 lbf ft) Loctite ®...
  • Page 234 22 TECHNICAL DATA Screw, combination instrument M10x1.25 21 Nm (15.5 lbf ft) bracket Screw, front footrest bracket M10x1.25 44 Nm (32.5 lbf ft) Loctite ® 243™ Screw, front footrest bracket / M10x1.25 49 Nm (36.1 lbf ft) engine bearer Screw, side stand bracket M10x1.25 25 Nm (18.4 lbf ft) Loctite...
  • Page 235 22 TECHNICAL DATA Nut, steering head M30x1 1st stage 45 Nm (33.2 lbf ft) 2nd stage (loosen, counterclock- wise) 2 turns 3rd stage 5 Nm (3.7 lbf ft)

  • Page 236: Declarations Of Conformity

    The full text of the Declaration of Conformity is available at the following Internet address. Certification website: http://www.ktm.com/210m1100 KTM AG hereby declares that the KTM RACE ON system wireless system conforms with the relevant guidelines. The full text of the Declaration of Conformity is available at the following Internet address.
  • Page 237 23 DECLARATIONS OF CONFORMITY 210M1100 FCC ID: 2AKR7‑210M1100 IC: 22291‑210M1100 BT‑ROUTER FCC ID: Z64‑2564N IC: 451I‑2564N KTM RACE ON system ‑ Active Key FCC ID: VFZKLGKZADI01 IC: 22239-KLGKZADI01 KTM RACE ON system ‑ Main Unit FCC ID: VFZKLGMZADI01 IC: 22239-KLGMZADI01 LC8 DASHBOARD...
  • Page 238 23 DECLARATIONS OF CONFORMITY 1 This device must not cause harmful interference. 2 This device must be able to absorb any received interference, including interference that potentially causes undesirable operation. This equipment has been tested and complies with the limits for Class B digital devices, in accordance with article 15 of the FCC regulations.

  • Page 239: Substances

    24 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 240 24 SUBSTANCES The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted. The use of premixed coolant is recommended. Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.
  • Page 241 24 SUBSTANCES Fork oil (SAE 5) Standard/classification – SAE ( p. 242) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Recommended supplier Motorex ® –...

  • Page 242: Auxiliary Substances

    25 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® –...
  • Page 243 25 AUXILIARY SUBSTANCES Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® –...

  • Page 244: Standards

    26 STANDARDS JASO T903 MA Different technical development directions required a separate 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 sepa- rate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 245: Index Of Special Terms

    Light, which enhances the visibility of the vehicle dur- ing the day but is not focused, and in contrast to low beam does not illuminate the road surface KTM MY RIDE System for wireless communication with appropriate cellphones and headsets for telephony and audio...

  • Page 246: List Of Abbreviations

    28 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 247: List Of Symbols

    29 LIST OF SYMBOLS 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The oil pressure warning lamp lights up red – The oil pressure is too low. 29.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.
  • Page 248 29 LIST OF SYMBOLS The idle indicator lamp lights up green – The transmission is in idle. The high beam indicator lamp lights up blue – The high beam is switched on.

  • Page 249: Index

    INDEX Brake fluid level INDEX front brake, checking ....139 ABS ....... 135 rear brake, checking .
  • Page 250 ......35 KTM MY RIDE ..... . . 63 Coolant Language .
  • Page 251 INDEX Cooling system ......186 Filler cap filling/bleeding ..... 194 closing .
  • Page 252 INDEX lifting with front lifting gear ... . 116 raising with the rear lifting gear ..115 Hand brake lever ..... . . 33 removing the rear from the lifting gear .
  • Page 253 INDEX Protective clothing ..... . 21 Spare parts ......23 Starting .
  • Page 254 INDEX Time Winter operation adjusting ......78 checks and maintenance steps ..209 Tire air pressure Work rules .
  • Page 255 *3213566en* 3213566en 05/2017 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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