KTM 390 Duke Series 2019 Owner's Manual
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KTM 390 Duke Series 2019 Owner's Manual

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OWNER'S MANUAL
2019
390 Duke
Art. no. 3213939en

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Summary of Contents for KTM 390 Duke Series 2019

  • Page 1 OWNER'S MANUAL 2019 390 Duke Art. no. 3213939en...
  • 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 vehicle that will continue giving you pleasure for a long time if you maintain it properly.
  • 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) KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS VIEW OF VEHICLE ........20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 9 View of vehicle, front left (example) ... 20 Symbols used ........9 View of vehicle, rear right Formats used........10 (example)........22 SAFETY ADVICE.......... 11 SERIAL NUMBERS ........
  • Page 6 Quick Selector 2 display ....58 6.10 Closing the fuel tank filler cap... 36 7.17 Menu..........58 6.11 Seat lock......... 37 7.17.1 KTM MY RIDE (optional) ....59 6.12 Tool set........... 37 7.17.2 Info ..........60 6.13 Grab handles ........38 7.17.3 Motorcycle ........
  • Page 7 TABLE OF CONTENTS 7.17.21 Shift Light ........78 10 SERVICE SCHEDULE ........ 109 7.17.22 Setting the time and date ..... 78 10.1 Additional information ....109 7.17.23 DRL ........... 81 10.2 Required work ....... 109 7.17.24 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......... 125 level ..........149 12.11 Cleaning the chain ......125 13.10 Adding rear brake fluid ....150 12.12 Checking the chain tension ..... 127 13.11 Checking the rear brake linings ..153 12.13 Adjusting the chain tension.....
  • Page 9 TABLE OF CONTENTS 15.10 Front ACC1 and ACC2 ....184 19.2 Checks and maintenance steps for winter operation......212 16 COOLING SYSTEM ........185 20 STORAGE ..........214 16.1 Cooling system ......185 20.1 Storage ......... 214 16.2 Checking the antifreeze and coolant level ........
  • Page 10 TABLE OF CONTENTS 25 AUXILIARY SUBSTANCES ......242 26 STANDARDS ..........244 27 INDEX OF SPECIAL TERMS ....... 245 28 LIST OF ABBREVIATIONS......246 29 LIST OF SYMBOLS........247 29.1 Red symbols........247 29.2 Yellow and orange symbols....247 29.3 Green and blue symbols....

  • Page 11: Means Of Representation 1

    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 a voltage measurement. Indicates a current measurement. Indicates the end of an activity, including potential rework. Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name ®...

  • Page 13: Safety Advice 2

    SAFETY ADVICE 2 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 Info Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the...

  • Page 15: Tampering Warning

    SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any...

  • Page 16: Protective Clothing

    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 17: Work Rules

    SAFETY ADVICE 2 In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses.

  • Page 18: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 19: Important Notes 3

    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 the KTM Dealer.net, otherwise any warranty coverage will become void.

  • Page 20: 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 21 IMPORTANT NOTES 3 A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 22: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V01275-10...
  • Page 23 VIEW OF VEHICLE 4 Combination instrument Clutch lever ( p. 27) Front rider’s seat Passenger seat Grab handles ( p. 38) Seat lock ( p. 37) Shift lever ( p. 39) Side stand ( p. 40) Engine number ( p. 25)

  • Page 24: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) V01276-10...
  • Page 25 VIEW OF VEHICLE 4 Tool set ( p. 37) Light switch ( p. 29) Menu switch ( p. 30) Turn signal switch ( p. 30) Horn button ( p. 31) Ignition and steering lock ( p. 32) Emergency OFF switch ( p.

  • Page 26: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 402408-10 Type label (EU/JP/AR/BR/CN/CO/MY/PH/TH) The type label is on the right of the frame behind the steering head. 402174-10...

  • Page 27: Engine Number

    SERIAL NUMBERS 5 (390 Duke AU) The type label is on the left of the frame behind the steer- ing head. 402772-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 402486-10...

  • Page 28: Key Number

    5 SERIAL NUMBERS Key number can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. If at least one ignition key is still available, a spare key can be produced.

  • Page 29: Controls 6

    CONTROLS 6 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 30: 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 31: Light Switch

    CONTROLS 6 Overview of the left combination switch Light switch ( p. 29) Menu switch ( p. 30) Turn signal switch ( p. 30) Horn button ( p. 31) F00785-10 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on –...

  • Page 32: 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 33: Horn Button

    CONTROLS 6 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 34: 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 is pressed – In this position, the • Electric starter button starter motor is actuated. F00789-10 Ignition and steering lock The ignition and steering lock is located in front of the upper triple...

  • Page 35: Locking The Steering

    CONTROLS 6 Steering locked LOCK – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed. 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.

  • Page 36: Unlocking The Steering

    6 CONTROLS Unlocking the steering – Insert the ignition key into the ignition and steering lock, press in, and turn to the right. Remove the ignition key. The handlebar can now be moved again. 400731-01 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable.
  • Page 37 CONTROLS 6 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 38: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Lift the fuel tank filler cap. 6.10 Closing the fuel tank filler cap Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. – Check that the fuel tank filler cap is locked cor- rectly after closing. –...

  • Page 39: Seat Lock

    CONTROLS 6 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 40: 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 foot pegs The passenger foot pegs can be folded up and down. Possible states Passenger foot pegs folded up –...

  • Page 41: Shift Lever

    CONTROLS 6 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 42: 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 located on the left of the vehicle. The side stand is used for parking the motorcycle.
  • Page 43 CONTROLS 6 Side stand folded in – This position is mandatory when riding • the motorcycle. The safety starting system is inactive.

  • Page 44: 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. 46) Display M01577-10 Activation and test Activation The combination instrument is activated when the ignition is switched on.

  • Page 45: Day-Night Mode

    COMBINATION INSTRUMENT 7 Day-Night mode Day mode is shown in a bright color. M01578-01 Night mode is shown in a dark color. Info The ambient light sensor in the combination instrument measures the brightness of the environment. The display is brightened, darkened or switched to the other mode depending on the light intensity measured by the ambient light sensor.

  • Page 46: Warnings

    7 COMBINATION INSTRUMENT Warnings Warnings appear on the top and/or bottom edge of the display; these are marked yellow or red depending on their relevance. Yellow warnings indicate errors or information which require prompt intervention or an adjustment to the riding style. Red warnings indicate errors or information which require immediate intervention.
  • Page 47 COMBINATION INSTRUMENT 7...

  • Page 48: Indicator Lamps

    7 COMBINATION INSTRUMENT Indicator lamps F00900-01...
  • Page 49 Malfunction indicator lamp lights up yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS warning lamp flashes if the ABS mode Super Moto is enabled.
  • Page 50 7 COMBINATION INSTRUMENT The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine. Alarm system indicator lamp flashes red – Status message on the alarm system (optional). The high beam indicator lamp lights up blue –...
  • Page 51 COMBINATION INSTRUMENT 7...

  • Page 52: Display

    7 COMBINATION INSTRUMENT Display M01580-11...
  • Page 53 COMBINATION INSTRUMENT 7 Speed ( p. 52) Shift warning light ( p. 52) The shift warning light is integrated in the tachometer display. Gear display Unit for the speed display Speed ( p. 53) Unit for the speedometer ODO display ( p.

  • Page 54: Speed

    7 COMBINATION INSTRUMENT Speed The speed is measured in revolutions per minute. M01581-10 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 55: Speed

    COMBINATION INSTRUMENT 7 ≤ 35 °C (≤ 95 °F) Coolant temperature < 1,000 km (< 620 mi) The shift warning 6,500 rpm light always flashes Coolant temperature > 35 °C (> 95 °F) > 1,000 km (> 620 mi) RPM1 shift warning flashes light RPM2 shift warning...

  • Page 56: 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 12-V battery is discon- nected from the vehicle or the fuse blows. M01581-12 7.11 Coolant temperature indicator The coolant temperature indicator consists of bars.

  • Page 57: Fuel Level Display

    COMBINATION INSTRUMENT 7 Info When all the bars light up, the warning ENGINE TEMP HIGH also appears. If the cooling system overheats, the maximum engine speed is limited. Possible states The engine is cold – Up to three bars light up. •...

  • Page 58: Time

    7 COMBINATION INSTRUMENT Info If the fuel level is getting low, the last segment flashes red and the following warning also appears LOW FUEL. The fuel level is displayed with a slight delay to prevent the indicator from constantly moving while riding. The fuel level display is not updated while the side stand is folded out or the emergency off switch is switched off.

  • Page 59: Favourites Display

    COMBINATION INSTRUMENT 7 7.14 Favourites display Up to eight items of information are shown in the Favourites dis- play. The Favourites display can be freely configured in the Favourites menu. Info One to four items of information selected are displayed on two lines.

  • Page 60: Quick Selector 2 Display

    7 COMBINATION INSTRUMENT 7.16 Quick Selector 2 display When the menu is closed, the Quick Selector 2 menu is opened by pressing the DOWN button. Press the BACK button to close Quick Selector 2. Info The Quick Selector 2 can be configured in the Quick Selec- tor 2 menu.

  • Page 61: Ktm My Ride (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. In the KTM MY RIDE menu, an appropriate cellphone or appropriate...

  • Page 62: Info

    7 COMBINATION INSTRUMENT 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. General information can be accessed in Info. V01161-01 7.17.3 Motorcycle...

  • Page 63: Settings

    COMBINATION INSTRUMENT 7 7.17.4 Settings 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. Favorites and quick selection can be configured in Settings.

  • Page 64: Pairing (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. – Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu.

  • Page 65: Phone (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. F01959-01 – Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu.
  • Page 66 7 COMBINATION INSTRUMENT phone is displayed in the Pairing menu. Press the SET button to start the pairing. Info The cellphone must be visible via Bluetooth ® for the cellphone to be found by the combination instrument. – A message appears on the combination instrument indicat- ing that this is now ready for pairing.

  • Page 67: Headset (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. F01960-01 – Press the UP or DOWN button until Pairing is marked. Press the SET button to open the menu.
  • Page 68 7 COMBINATION INSTRUMENT – The combination instrument starts searching for a suitable headset. If the search was successful, the name of the head- set is displayed in the Pairing menu. Press the SET button to select the device. Press the SET button again to confirm the Confirm menu item.

  • Page 69: 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. V01165-01 Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity.
  • Page 70 7 COMBINATION INSTRUMENT – Press the UP or DOWN button until Audio is marked. Press the SET button to open the menu. – Press and hold the UP button to increase the audio volume. – Press and hold the DOWN button to reduce the audio volume. –...

  • Page 71: Telephony (Optional)

    COMBINATION INSTRUMENT 7 7.17.10 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 72: General Info

    7 COMBINATION INSTRUMENT 7.17.11 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 73: Trip 2

    COMBINATION INSTRUMENT 7 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. 7.17.13 Trip 2 – Press the SET button when the menu is closed. –...

  • Page 74: Warning

    7 COMBINATION INSTRUMENT Press and All entries in the Trip 2 menu are reset. hold the SET button for 3-5 seconds. 7.17.14 Warning Condition • Message or warning is present. – Press the SET button when the menu is closed. –...

  • Page 75: Abs

    COMBINATION INSTRUMENT 7 7.17.15 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 76: Favourites

    7 COMBINATION INSTRUMENT 7.17.16 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 77: Quick Selector 2

    COMBINATION INSTRUMENT 7 When the menu is closed, the Quick Selector 1 menu is opened by pressing the UP button. 7.17.18 Quick Selector 2 Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. –...

  • Page 78: Bluetooth (Optional)

    V01171-01 off. Info The Bluetooth ® function can only be used in conjunction with KTM MY RIDE (optional). When the Bluetooth ® function is switched on and the device is connected, the Bluetooth ® symbol appears in the display...

  • Page 79: Display Theme

    COMBINATION INSTRUMENT 7 7.17.20 Display Theme 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 80: Shift Light

    7 COMBINATION INSTRUMENT 7.17.21 Shift Light Condition • The motorcycle is stationary. • ODO > 1000 km (621 miles). – 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 COMBINATION INSTRUMENT 7 – 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

    COMBINATION INSTRUMENT 7 7.17.23 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 SET button to switch the daytime running light on or off. 7.17.24 Distance Condition •...

  • Page 85: Temperature

    COMBINATION INSTRUMENT 7 7.17.25 Temperature 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 – Activate the menu item using the UP or DOWN button. – Press the SET button to confirm the desired unit. 7.17.27 Language Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. –...

  • Page 87: Service

    COMBINATION INSTRUMENT 7 7.17.28 Service 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 88 7 COMBINATION INSTRUMENT Info The current KTM PowerParts and the available software for your vehicle can be found on the KTM website.

  • Page 89: Preparing For Use 8

    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 90 When using the vehicle, remember that others may feel disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. The delivery certificate and the Service and Manufacturer Warranty booklet must be transferred with the vehicle.

  • Page 91: Running In The Engine

    PREPARING FOR USE 8 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 92 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 93 PREPARING FOR USE 8 – If luggage is carried, ensure 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 maximum permissible weight and maximum permissible axle loads. Guideline Maximum permissible overall weight 355 kg (783 lb.)

  • Page 94: Riding Instructions

    9 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 roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 95: Starting

    RIDING INSTRUCTIONS 9 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 effective exhaust extraction when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis- charged or missing.
  • Page 96 9 RIDING INSTRUCTIONS – Unlock the steering. ( p. 34) – Sit on the vehicle, take the weight off of the side stand, and move it all the way up with your foot. – Turn the emergency OFF switch to the position –...

  • Page 97: Starting Off

    RIDING INSTRUCTIONS 9 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 98: 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 99 RIDING INSTRUCTIONS 9 Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. – Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot pegs and holds on to the rider or the grab handles. –...
  • Page 100 Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop.
  • Page 101 RIDING INSTRUCTIONS 9 – 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 The gear positions can be seen in the figure.

  • Page 102: Applying The Brakes

    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- ating safety (warning) message was detected.
  • Page 103 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 104 9 RIDING INSTRUCTIONS Info When the ABS is enabled, maximum braking power can be achieved even with low road grip surfaces such as sandy, wet, or slippery terrain without locking the wheels. Warning Danger of accidents The rear wheel can lock due to the engine braking effect. –...

  • Page 105: Stopping, Parking

    RIDING INSTRUCTIONS 9 Stopping, parking Warning Risk of injury People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. – Lock the steering and remove the ignition key if you leave the vehicle unattended. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.

  • Page 106: Transport

    9 RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...
  • Page 107 RIDING INSTRUCTIONS 9 Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...

  • Page 108: Refueling

    9 RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.
  • Page 109 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.) Note Environmental hazard Improper handling of fuel is a danger to the environment.
  • Page 110 9 RIDING INSTRUCTIONS – Switch off the engine. – Open fuel tank filler cap. ( p. 34) – 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.

  • Page 111: Service Schedule 10

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
  • Page 112 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 rear brake fluid level. ( p. 149) ○ ● ● ● ●...

  • Page 113: Recommended Work

    Final check: Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Set the service interval display.
  • Page 114 10 SERVICE SCHEDULE 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 link fork. ● ● Check the link fork bearing for play. ● ● Check the wheel bearing for play. ○...

  • Page 115: Tuning The Chassis 11

    TUNING THE CHASSIS 11 11.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris- tic. – Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Info The spring preload defines the initial status of the spring operation on the shock absorber.

  • Page 116: 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 117 TUNING THE CHASSIS 11 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 118: Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with 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 119: Lifting The Motorcycle With The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 12 – 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 120 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 (69329965100) Info Always raise the motorcycle at the rear first. –...

  • Page 121: Taking The Motorcycle Off The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 12 12.4 Taking the motorcycle off 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 122: 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. 116) 12.5 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 123 SERVICE WORK ON THE CHASSIS 12 Main work – Push dust boots of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside 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 124: Removing The Passenger Seat

    12 SERVICE WORK ON THE CHASSIS – Remove the rear of the motorcycle from the lifting gear. p. 116) 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 lift it off.

  • Page 125: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS 12 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 passenger seat downward until it clicks into place. Warning Danger of accidents The seat can come loose from the anchoring if it is not mounted correctly.

  • Page 126: 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 127: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12 12.10 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 125) 400678-01 12.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.
  • Page 128 12 SERVICE WORK ON THE CHASSIS Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 129: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 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 130: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 128) – Remove the rear of the motorcycle from the lifting gear. p. 116) 12.13 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.
  • Page 131 SERVICE WORK ON THE CHASSIS 12 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 132: 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. 116) 12.14 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 133 SERVICE WORK ON THE CHASSIS 12 – Shift the transmission to neutral position. – 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 134 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 135: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 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 clutch lever forward and turn the adjusting wheel.

  • Page 136: 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 137 SERVICE WORK ON THE CHASSIS 12 – 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) F00797-10...

  • Page 138: 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 specified tire pressure. –...
  • Page 139 BRAKE SYSTEM 13 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 140: Adjusting The Basic Position Of The Hand Brake Lever

    Do not make any adjustments while riding. F00784-13 13.3 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.)
  • Page 141 BRAKE SYSTEM 13 – Check the front and rear brake disc thickness at multiple points for the dimension Info Wear will reduce the thickness of the brake disc at con- tact surface of the brake linings. Brake discs - wear limit front 4.5 mm (0.177 in) 400480-10...

  • Page 142: Checking The Front Brake Fluid Level

    – 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.) – Move the brake reservoir mounted on the handlebar into a hori- zontal position.

  • Page 143: Adding The 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.) Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 144 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.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 145 BRAKE SYSTEM 13 Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane – Add brake fluid to level Guideline 5 mm (0.2 in) Dimension F00862-10 Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 146: 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 147: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 13.7 Checking the free travel of 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 148 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 149: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 13 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 150 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 151: 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 152: 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 153 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.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 154 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 155: 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 156 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 157: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 116) – Lift the motorcycle with the front lifting gear. ( p. 117) Main work – Remove screws with washers and push the fender slightly to the side.

  • Page 158: Installing The Front Wheel

    14 WHEELS, TIRES Info Do not actuate 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 159 WHEELS, TIRES 14 – Clean the thread of the wheel spindle and screw – Clean and grease the wheel spindle. Long-life grease ( p. 242) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. –...

  • Page 160: Removing The Rear Wheel

    14 WHEELS, TIRES – Remove the rear of the motorcycle from the lifting gear. p. 116) – 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 161 WHEELS, TIRES 14 – Remove screw and pull wheel speed sensor out of the hole. – Remove nut and washer. – Take off 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 162: 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 163 WHEELS, TIRES 14 – Clean the contact areas on the brake caliper bracket and link fork. – Mount the damping rubber and rear sprocket carrier on the rear wheel. – Insert the spacers. – Position the rear wheel. The brake linings are correctly positioned. –...
  • Page 164 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 the 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 165: Checking The Rear Hub Damping Rubber Pieces

    WHEELS, TIRES 14 – 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. 116) – Check the chain tension. ( p.
  • Page 166 14 WHEELS, TIRES Main work – Check bearing » If the bearing is damaged or worn: – Change the bearing. – Check the damping rubber pieces of the rear hub for dam- age and wear. » If the damping rubber pieces of the rear hub are damaged or worn: F00868-10 –...

  • Page 167: 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 168 14 WHEELS, TIRES Info The type, condition, and pressure of the tires all have a major impact on the handling characteristic 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 169: Checking Tire 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 170 14 WHEELS, TIRES – Remove the protection cap. – Check the tire pressure when the tires are cold. Tire pressure when solo front 2.0 bar (29 psi) rear 2.0 bar (29 psi) Tire pressure with passenger / full payload front 2.0 bar (29 psi) 400695-01 rear...

  • Page 171: Electrical System 15

    ELECTRICAL SYSTEM 15 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 172: Removing The 12-V Battery

    15 ELECTRICAL SYSTEM This is controlled by the ambient light 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 12-V battery Warning...
  • Page 173 ELECTRICAL SYSTEM 15 – Remove the front rider's seat. ( p. 123) Main work – Disconnect negative cable from the 12-V battery. V01273-10 – Pull back positive terminal cover – Disconnect positive cable from the 12-V battery. – Detach rubber strap –...

  • Page 174: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM 15.3 Installing the 12-V battery Main work – Position the 12-V battery in the battery compartment. 12-V battery (ETZ‑9‑BS) ( p. 228) – Attach rubber strap – Position positive cable and mount and tighten the screw. – Position positive terminal cover V01274-11 –...

  • Page 175: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 – Set the time and date. ( p. 78) 15.4 Charging the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. –...
  • Page 176 15 ELECTRICAL SYSTEM Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety valves.
  • Page 177 ELECTRICAL SYSTEM 15 Main work – Connect battery charger to the 12-V battery. Switch on battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the open- circuit voltage, the starting ability of the 12-V battery, and the alternator.

  • Page 178: Changing The Abs Fuses

    15 ELECTRICAL SYSTEM Finishing work – Mount the front rider's seat. ( p. 124) – Mount the passenger seat. ( p. 123) – Set the time and date. ( p. 78) 15.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. –...
  • Page 179 ELECTRICAL SYSTEM 15 To change the fuse of the ABS hydraulic unit: – Take off the protection cap and remove fuse Info A faulty fuse has a burned-out fuse wire Warning Fire hazard Incorrect fuses overload the electrical F00848-10 system. – Only use fuses with the required ampere value.
  • Page 180 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 181: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 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 the ignition by turning the ignition key to the posi- tion –...
  • Page 182 15 ELECTRICAL SYSTEM Main work – Open fuse box cover – Remove the faulty 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 - 15 A - radiator fan...
  • Page 183 ELECTRICAL SYSTEM 15 Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert a spare fuse with the correct rating. Fuse (75011088010) ( p.

  • Page 184: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 15.7 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light- colored wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first marking.

  • Page 185: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 15.8 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 182) Main work – Turn adjusting screw to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range. If you have a payload, you may have to correct the headlight range.

  • Page 186: Diagnostics Connector

    15 ELECTRICAL SYSTEM 15.9 Diagnostics connector Diagnostics connector is located under the passenger seat. H01906-10 15.10 Front ACC1 and ACC2 Installation location – Power supplies ACC1 and ACC2 front are located on the left of the vehicle, behind the cover under the fuel tank. E01189-10...

  • Page 187: Cooling System 16

    COOLING SYSTEM 16 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 188 16 COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan which is activated at high temperature. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. Info If the cooling system overheats, the maximum engine speed is limited.

  • Page 189: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM 16 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 190 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 191 COOLING SYSTEM 16 – 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 192: 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 193 COOLING SYSTEM 16 – 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 194: 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 195: Filling/Bleeding The Cooling System

    COOLING SYSTEM 16 Main work – Position the motorcycle vertically. – Place an appropriate 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 196 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 197 COOLING SYSTEM 16 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 effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 198: Changing The Coolant

    16 COOLING SYSTEM 16.6 Changing 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 199 COOLING SYSTEM 16 Main work – Position the motorcycle vertically. – Place an appropriate container under the engine. – Remove screw with the seal ring. F00857-10 – Remove radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
  • Page 200 16 COOLING SYSTEM – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in the coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately.
  • Page 201 COOLING SYSTEM 16 – Stop the engine and allow it to cool down. – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Remove cap of the compensating tank and top up the coolant level up to the MAX marking.

  • Page 202: Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the clutch lever play Note Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip. – Check the free travel of the clutch lever each time before using the motorcycle. –...

  • Page 203: Adjusting Play In The Clutch Lever

    TUNING THE ENGINE 17 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 204: 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 205: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 18 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 206 18 SERVICE WORK ON THE ENGINE Main work – Place an appropriate 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 207 SERVICE WORK ON THE ENGINE 18 – Remove screws . Take off 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 208 18 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring, and fill up with engine oil. Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50) p. 239) – Mount and tighten the filler plug together with the O-ring. Danger 401955-12 Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 209: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 18.3 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Main work – Remove filler plug with the O-ring, and fill up with engine oil.
  • Page 210 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 effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 211: Cleaning, Care 19

    CLEANING, CARE 19 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 212 19 CLEANING, CARE – Close off the exhaust system to keep water from entering. – Remove loose dirt first with a soft jet of water. – Spray heavily soiled parts with a normal commercial motorcy- cle cleaner and then brush off with a soft brush. Motorcycle cleaner ( p.
  • Page 213 CLEANING, CARE 19 – 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 214: 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. 243) – Lubricate the ignition and steering lock. Universal oil spray ( p.
  • Page 215 CLEANING, CARE 19 – Clean the motorcycle. ( p. 209) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly clean the motorcycle and, in particular, the brake calipers and brake linings, after they have cooled down and without removing them, with cold water and dry carefully.

  • Page 216: Storage

    20 STORAGE 20.1 Storage Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them per- formed. 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).
  • Page 217 – Store vehicle in a dry location that is not subject to large fluc- tuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 116) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 218: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 119) – Remove the rear of the motorcycle from the lifting gear. p. 116) – Install the 12-V battery. p. 172) –...

  • Page 219: Troubleshooting 21

    Carry out the start procedure. p. 93) – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine has too little power Air filter is very dirty Change the air filter. –...
  • Page 220 – 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 221 TROUBLESHOOTING 21 Faults Possible cause Action – High oil consumption Engine oil too thin (low viscos- Change the engine oil and oil filter, ity) clean the oil screens. p. 203) – Headlight and position light are Fuse 6 blown Change the fuses of individual power not functioning consumers.

  • Page 222: 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 223: Engine Tightening Torques

    TECHNICAL DATA 22 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 Electronic 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 224 22 TECHNICAL DATA Screw, gear sensor 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 225 TECHNICAL DATA 22 Screw, clutch cover 12 Nm (8.9 lbf ft) Screw, clutch spring 10 Nm (7.4 lbf ft) Screw, engine case M6x35 12 Nm (8.9 lbf ft) Screw, engine case M6x75 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, engine vent plate 10 Nm (7.4 lbf ft) Loctite...
  • Page 226 22 TECHNICAL DATA Screw, timing chain tensioner 12 Nm (8.9 lbf ft) Screw, timing chain tensioning rail 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, unlocking of timing chain 6 Nm (4.4 lbf ft) tensioner Screw, valve cover 12 Nm (8.9 lbf ft) Screw, water pump cover 12 Nm (8.9 lbf ft) Nut, exhaust flange...

  • Page 227: Capacities

    TECHNICAL DATA 22 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™ Screw plug, cam lever axis M10x1 10 Nm (7.4 lbf ft) Spark plug...

  • Page 228: Coolant

    22 TECHNICAL DATA 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 238) 22.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 229: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Lattice frame of steel tubes, powder-coated WP Suspension Fork WP Suspension Shock absorber Brake system front Disc brake with 4-piston brake caliper rear Disc brake with single-pot brake caliper, floating Suspension travel front 142 mm (5.59 in) rear 150 mm (5.91 in) Brake discs - diameter...

  • Page 230: Electrical System

    22 TECHNICAL DATA rear 2.2 bar (32 psi) Secondary ratio 15:45 Chain 5/8 x 1/4” (520) X‑ring Steering head angle 65° Wheelbase 1,357 ± 15.5 mm (53.43 ± 0.61 in) Seat height, unloaded 830 mm (32.68 in) Ground clearance, unloaded 175 mm (6.89 in) Dry weight 149 kg (328 lb.)

  • Page 231: Tires

    110/70 R 17 M/C 54H TL 150/60 R 17 M/C 66H TL Continental ContiMotion Continental ContiMotion 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 93301000144 Fork...

  • Page 232: Shock Absorber

    22 TECHNICAL DATA Fork oil 450 ml (15.21 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 240) 22.8 Shock absorber Shock absorber article number 93304010000 Shock absorber WP Suspension Spring preload Standard 5 clicks Static sag 14 mm (0.55 in) Riding sag 47 mm (1.85 in) Fitted length...
  • Page 233 TECHNICAL DATA 22 Screw, fuel tank cover 4 Nm (3 lbf ft) Screw, outer clutch cable guide 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, side stand switch 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, tail light 5 Nm (3.7 lbf ft) Nut, foot brake lever adjustment 9 Nm (6.6 lbf ft)
  • Page 234 22 TECHNICAL DATA Screw, damper block 8 Nm (5.9 lbf ft) Screw, engine sprocket cover 8 Nm (5.9 lbf ft) Screw, foot brake cylinder 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, front fender 7 Nm (5.2 lbf ft) Screw, front seat fixing 6 Nm (4.4 lbf ft) Screw, front spoiler...
  • Page 235 TECHNICAL DATA 22 Screw, main silencer retaining 9 Nm (6.6 lbf ft) bracket Screw, protective plate 8 Nm (5.9 lbf ft) Screw, radiator holder 10 Nm (7.4 lbf ft) Screw, radiator shield 7 Nm (5.2 lbf ft) Screw, rear ABS sensor wheel 8 Nm (5.9 lbf ft) Loctite ®...
  • Page 236 22 TECHNICAL DATA Screw, front brake disc 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, front seat fixing 25 Nm (18.4 lbf ft) Screw, front wheel spindle 25 Nm (18.4 lbf ft) Screw, fuel tank 20 Nm (14.8 lbf ft) Screw, grab handle 22 Nm (16.2 lbf ft) Screw, handlebar clamp...
  • Page 237 TECHNICAL DATA 22 Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, engine bearer 49 Nm (36.1 lbf ft) Loctite ® 243™ Fitting, handlebar support M10x1.25 21 Nm (15.5 lbf ft) Fitting, shock absorber, bottom M10x1.25 51 Nm (37.6 lbf ft) Loctite ®...
  • Page 238 22 TECHNICAL DATA Adjusting ring, link fork bearing M22x1 Tighten and ensure that there is no play 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 239: Declarations Of Conformity 23

    COBO SpA hereby declares that the BT‑ROUTER wireless system conforms with the relevant guidelines. The full text of the Declaration of Conformity is available at the following Internet address. Certification website: http://www.ktm.com/btrouter JNS Instruments Ltd. hereby declares that the 210M1100 wireless system conforms with the relevant guidelines.

  • Page 240: 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 241 SUBSTANCES 24 The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted. The use of premixed coolant is recommended. Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.
  • Page 242 24 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 244) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Gasohol 95 E20 (RON 95) Standard/classification –...
  • Page 243 SUBSTANCES 24 – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 244: Auxiliary Substances

    25 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX...
  • Page 245 AUXILIARY SUBSTANCES 25 Preserving materials for paints, metal and rubber Recommended supplier MOTOREX ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX ®...

  • Page 246: Standards

    26 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 247: Index Of Special Terms 27

    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 248: 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 249: List Of Symbols 29

    Malfunction indicator lamp lights up yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS warning lamp flashes if the ABS mode Super Moto is enabled.
  • Page 250 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 251: Index

    INDEX INDEX Brake discs 12-V battery checking ......138 charging ......173 Brake fluid installing .
  • Page 252 Info ......60 KTM MY RIDE ..... . . 59 checking .
  • Page 253 INDEX warnings ......44 changing ......203 Combination switch .
  • Page 254 INDEX Front wheel Implied warranty ......17 installing ......156 Indicator lamps .
  • Page 255 INDEX Owner's Manual ......16 Riding ......96 starting off .
  • Page 256 INDEX on the right side of the handlebar ..31 Type label ......24 Use definition .
  • Page 257 *3213939en* 3213939en 01/2019 KTM Sportmotorcycle GmbH Photo: 5230 Mattighofen/Austria Mitterbauer/KISKA/KTM http://www.ktm.com...

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