KTM 890 DUKE GP 2022 Owner's Manual
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KTM 890 DUKE GP 2022 Owner's Manual

KTM 890 DUKE GP 2022 Owner's Manual

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OWNER'S MANUAL
2022
890 DUKE
890 DUKE GP
Art. no. 3214542en

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Summary of Contents for KTM 890 DUKE GP 2022

  • Page 1 OWNER'S MANUAL 2022 890 DUKE 890 DUKE GP Art. no. 3214542en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Switches on the right side of the TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 handlebar........18 Symbols used ........5 6.5.1 Start button/emergency OFF Formats used........5 switch......... 18 Ignition and steering lock....19 SAFETY ADVICE..........6 Opening fuel tank filler cap....
  • Page 5 Removing the rear of the motorcycle 7.16.31 Shift Light ........41 from the lifting gear ......66 7.16.32 KTM MY RIDE (optional) ....42 13.3 Lifting the motorcycle with the front lifting gear ........66 7.16.33 Pairing (optional) ......42 13.4...
  • Page 6 TABLE OF CONTENTS 16.6 Changing the ABS fuses ....96 23 TECHNICAL DATA........121 16.7 Changing the fuses of individual 23.1 Engine .......... 121 electrical power consumers ....97 23.2 Engine tightening torques ....122 16.8 Loosening the headlight mask with 23.3 Capacities ........

  • Page 7: Means Of Representation 1

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on race courses. This vehicle is not suitable for offroad use. Info This vehicle is only authorized for operation on public roads in its homologated version. Misuse The vehicle must only be used as intended.

  • Page 9: Tampering Warning

    An appropriate driver's license is needed to drive 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 10: 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. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
  • Page 11 The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 12: Important Notes

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) F03791-10 Combination instrument ( p. 23) Ignition and steering lock ( p. 19) Clutch lever ( p. 15) Seat lock ( p. 20) Side stand ( p. 22) Shift lever ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) F03790-10 Tool set ( p. 21) Fuel tank filler cap Combination switch ( p. 15) Start button/emergency OFF switch ( p. 18) Hand brake lever ( p. 15) Level viewer, engine oil Foot brake lever ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 402324-10 Type label The type label is located on the steering head on the left. The type label Australia is located on the frame behind the steering head at the top left.

  • Page 16: Fork Part Number

    5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 402295-10 Shock absorber article number Shock absorber article number is on the left side of the shock absorber. F03782-10 Steering damper article number Steering damper article number is embossed on the underside of the steering damper.

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. V01187-10 Hand brake lever The hand brake lever is located on the right side of the han- dlebar. The front brake is engaged using the hand brake lever. V01188-10 Throttle grip The throttle grip...

  • Page 18: Light Switch

    6 CONTROLS 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch in position . In this position, the low beam and the tail light are switched High beam on – Push the light switch to position In this position, the high beam and the tail light are switched on.
  • Page 19 CONTROLS 6 To switch off the cruise control system function, press the cruise control system tip switch to the left. In addition, the cruise control system function is deactivated when one of the following events occurs: – Operating the hand brake lever –...

  • Page 20: Menu Buttons

    6 CONTROLS 6.4.4 Menu buttons The menu buttons are 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 21: Ignition And Steering Lock

    CONTROLS 6 Start button/emergency OFF switch on (middle posi- tion) – This position is required for operation; the igni- tion circuit is closed. Starter motor on (lower position) – In this position, the starter motor is actuated. Ignition and steering lock The ignition and steering lock is located in front of the upper triple clamp.

  • Page 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Lift cover of the fuel tank filler cap and insert the ignition key into the lock. Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced. – Push down on the fuel tank filler cap to take pressure off the ignition key.

  • Page 23: Tool Set

    CONTROLS 6 6.10 Tool set The tool set is located under the passenger seat. F03784-10 6.11 Grab handle The grab handle is used for maneuvering the motorcycle. If you carry a passenger, the passenger can hold onto the grab handles during the trip. V01225-10 6.12 Passenger foot pegs...

  • Page 24: Foot Brake Lever

    6 CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. V01271-10 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 402177-10 6.15 Side stand...

  • Page 25: Combination Instrument 7

    (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop. The oil pressure warning lamp always lights up as long as the engine is not running. If the engine is running and the...

  • Page 26: Warnings

    7 COMBINATION INSTRUMENT Night mode is shown in a dark color. Info The ambient light sensor in the combination instrument measures the brightness of the environment and automat- ically switches the display to day or night mode. The dis- play is brightened, darkened or switched to the other mode depending on the brightness measured by the ambient light sensor.
  • Page 27 109) is not enabled or is currently interven- ing. The TC indicator lamp also lights up if a malfunction is detected. Contact an authorized KTM workshop. The TC indicator lamp flashes if MTC actively engages or if the Launch Control p. 54) is activated.

  • Page 28: Display

    7 COMBINATION INSTRUMENT Display F02747-10 Info The figure shows the start screen of the combination instrument. If the menu is opened, the speed is still displayed. Gear display Heated grip (optional) ( p. 27) Cruise control indicator (optional) ( p. 28) Bluetooth ®...

  • Page 29: Track Display (Optional)

    COMBINATION INSTRUMENT 7 TRACK Display (optional) F02748-10 Info The figure shows the start screen of the combination instrument in active riding mode TRACK (optional). If the menu is opened, the speed is still displayed. Throttle response (optional) ( p. 110) Slip adjustment (optional) ( p.

  • Page 30: Cruise Control Indicator (Optional)

    7 COMBINATION INSTRUMENT Cruise control indicator (optional) When cruise control (optional) is activated, the operating mode is shown on the combination instrument display. Cruise control is operated using the cruise control tip switch p. 16). F02755-10 7.10 Fuel level display The fuel level indicator consists of bars.

  • Page 31: Trip Odometer

    COMBINATION INSTRUMENT 7 Engine hot – Six to eight bars light up. • Engine very hot – All eight bars flash orange. • 7.12 Trip odometer Trip 1 is displayed in the start screen as a trip odometer. This can- not be changed.

  • Page 32: Menu

    7 COMBINATION INSTRUMENT The shift warning 6,500 rpm light always lights up 7.16 Menu Info Press the SET button to open the menu. Navigate through the menu using the UP button the DOWN button Press the BACK button to close the current menu or the menu overview.

  • Page 33: Trip 2

    COMBINATION INSTRUMENT 7 7.16.3 Trip 2 – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 34: Settings

    ® Condition • The motorcycle is stationary. • Function KTM MY RIDE (optional) activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu.

  • Page 35: Temperature

    COMBINATION INSTRUMENT 7 7.16.8 Temperature Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 36: 7.16.11 Language

    7 COMBINATION INSTRUMENT 7.16.11 Language Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 37: 7.16.14 Tpms Warning

    Make sure that the daytime running light is deac- tivated with the diagnostics tool when the menu item is not available, but the low beam is required. (Your authorized KTM workshop will be glad to help.) – Note the legal regulations regarding the daytime running light.

  • Page 38: Quick Selector 1

    7 COMBINATION INSTRUMENT 7.16.15 Quick Selector 1 Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 39: 7.16.17 Set Favorites

    COMBINATION INSTRUMENT 7 7.16.17 Set Favorites Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 40: 7.16.20 Extra Functions

    V01126-01 tions. Info The optional extra functions are listed in Extra functions. The current KTM PowerParts and the available software for your vehicle can be found on the KTM website. 7.16.21 Warnings Condition • At least one warning present. –...

  • Page 41: Track (Optional)

    COMBINATION INSTRUMENT 7 Info Do not open the throttle during the selection. 7.16.23 Track (optional) Condition • The TRACK riding mode (optional) is activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Ride Mode menu is marked on the display.

  • Page 42: Heated Grips (Optional)

    7 COMBINATION INSTRUMENT 7.16.26 Heated Grips (optional) Condition • The Heated Grips menu activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Motorcycle menu is marked on the display. Press the SET button to open the menu. –...

  • Page 43: 7.16.29 Abs Mode

    COMBINATION INSTRUMENT 7 7.16.29 ABS Mode Condition • The motorcycle is stationary. • ABS is switched on. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Motorcycle menu is marked on the display. Press the SET button to open the menu. –...

  • Page 44: Ktm My Ride (Optional)

    Press the SET button when the menu is closed. – Press the UP or DOWN button until the KTM MY RIDE menu is marked on the display. Press the SET button to open the menu. In KTM MY RIDE, an appropriate cellphone or headset can be paired via Bluetooth ®...

  • Page 45: Audio Player (Optional)

    Headset connected to a suitable audio device. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the KTM MY RIDE menu is marked on the display. Press the SET button to open the menu. H02860-01 Warning Danger of accidents Headphone volume which is too...

  • Page 46: Telephony (Optional)

    The audio function can be added to Quick Selector 1 or Quick Selector 2 for easier operation. 7.16.35 Telephony (optional) Condition • Function KTM MY RIDE (optional) activated. Bluetooth ® • (optional) switched on. •...

  • Page 47: Ergonomics 8

    Info V01210-11 KTM recommends the front handlebar position when using the vehicle on a race track. Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk.

  • Page 48: Adjusting The Basic Position Of The Clutch Lever

    8 ERGONOMICS Adjusting the basic position of the clutch lever – Push the clutch lever forward. – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 49: Checking The Basic Position Of The Shift Lever

    ERGONOMICS 8 – Detach spring – Loosen nut Press the foot brake lever downwards to make this eas- ier. – Turn the push rod to set the basic position of the foot brake lever. V01229-10 Info The range of adjustment is limited. The screw must be screwed in by at least five full turns.

  • Page 50: Adjusting The Basic Position Of The Shift Lever

    8 ERGONOMICS – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the gear shift lever. Distance between shift lever 10 … 20 mm (0.39 … and upper edge of boot 0.79 in) »...

  • Page 51: Preparing For Use 9

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 52: Running In The Engine

    9 PREPARING FOR USE – Run the engine in. ( p. 50) 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) 6,500 rpm After the first: 1,000 km (620 mi) 9,800 rpm –...
  • Page 53 PREPARING FOR USE 9 Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system. – If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

  • Page 54: 10 Riding Instructions

    10 RIDING INSTRUCTIONS 10.1 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 55: Starting Off

    RIDING INSTRUCTIONS 10 – Take the motorcycle off the side stand and sit on the motorcy- cle. – Make sure that the start button/emergency OFF switch is in the middle position – Switch on the ignition by turning the ignition key to the posi- tion Guideline To avoid malfunctions in the control unit communication, do...

  • Page 56: Launch-Control (Optional)

    10 RIDING INSTRUCTIONS 10.4 Launch‑Control (optional) Launch Control is a vehicle electronics function. Launch control adjusts the engine speed in order to achieve the best possible acceleration. Launch control can be used for starting off for a maximum of three times in succession.

  • Page 57: Quickshifter + (Optional)

    RIDING INSTRUCTIONS 10 10.6 Quickshifter + (optional) If the quickshifter + is activated, you can shift up and down with- out actuating the clutch. Because there is no need to close the throttle grip, uninterrupted gear shifts are possible. The quickshifter + uses the shifter shaft position to check whether or not a shift should be initiated, and sends a corresponding signal to the engine control.
  • Page 58 10 RIDING INSTRUCTIONS Warning Danger of accidents A risky riding style constitutes a major risk. – Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as possible. Warning Danger of accidents Cold tires have reduced road grip. –...
  • Page 59 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. – Shift into a higher gear when conditions allow (incline, road situation, etc.).

  • Page 60: Engine Traction Torque Control (Msr)

    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 61: Stopping, Parking

    RIDING INSTRUCTIONS 10 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 62: Transporting

    10 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 63: Towing In The Event Of A Breakdown

    RIDING INSTRUCTIONS 10 – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away. 401448-01 10.12 Towing in the event of a breakdown Note Danger of damage Towing away using a towing vehicle is not an appropriate vehicle recovery method. Damage to the drive train or transmission may occur during towing.
  • Page 64 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 65: Service Schedule 11

    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 66: Recommended Work

    ● ● ● Set the service interval display. ○ ● ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ● Periodic interval 11.3 Recommended work every 48 months every 12 months every 30,000 km (18,600 mi)

  • Page 67: Tuning The Chassis 12

    TUNING THE CHASSIS 12 12.1 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 68: 13 Service Work On The Chassis

    13 SERVICE WORK ON THE CHASSIS 13.1 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 69: Taking The Motorcycle Off The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 13 13.4 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. – Secure the motorcycle against falling over. –...

  • Page 70: Removing The Passenger Seat

    13 SERVICE WORK ON THE CHASSIS 13.6 Removing the passenger seat Info The passenger seat cover is also included for the special model. If it is not required to carry a passenger, the passenger seat cover can be used instead of the passenger seat.

  • Page 71: Removing The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 13 13.8 Removing the front rider's seat Preparatory work – Remove the passenger seat. ( p. 68) Main work – Remove screws – Raise the rear of the front rider's seat, pull the seat back, and lift it off.

  • Page 72: Checking The Chain For Dirt

    13 SERVICE WORK ON THE CHASSIS 13.10 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 70) 400678-01 13.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...

  • Page 73: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 13 13.12 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 74: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    13 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 66) – Check the chain tension. ( p. 71) Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right.
  • Page 75 SERVICE WORK ON THE CHASSIS 13 – Shift the transmission to neutral position. – Pull on the lower chain section with the specified weight Guideline Weight of chain wear mea- 15 kg (33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 76 13 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If continuous signs of wear to the chain are visible on the chain sliding guard in the area marked: – Replace the chain sliding guard. »...

  • Page 77: Brake System 14

    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 pressure. –...

  • Page 78: 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 front and rear brake disc thickness at multiple...

  • Page 79: Adding Front Brake Fluid

    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 80: 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 81: 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 82 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 83: 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 84: 15 Wheels, Tires

    15 WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 66) – Lift the motorcycle with the front lifting gear. ( p. 66) Main work – Remove screw and pull wheel speed sensor out of the hole.

  • Page 85: Installing The Front Wheel

    WHEELS, TIRES 15 15.2 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. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 86: Removing The Rear Wheel

    15 WHEELS, TIRES – Position both brake calipers. The brake linings are correctly positioned. – Mount screws on both sides but do not tighten yet. Guideline Screw, front M10x1.25 45 Nm (33.2 lbf ft) Loctite ® 243™ brake caliper – Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.

  • Page 87: Installing The Rear Wheel

    WHEELS, TIRES 15 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. – Remove screw and pull wheel speed sensor out of the hole. – Remove nut . Take off chain adjuster –...
  • Page 88 15 WHEELS, TIRES Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel. – Actuate the foot brake several times before going on a ride until you can feel a firm pressure point. Main work –...

  • Page 89: Checking The Rear Hub Damping Rubber Pieces

    WHEELS, TIRES 15 Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. Finishing work –...

  • Page 90: 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 91: 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 years at the latest, regardless of the actual state of H01144-10 wear.
  • Page 92 15 WHEELS, TIRES We recommend transporting the broken down vehicle to the near- est workshop instead of using tire repair spray. (Option: With TPMS) Note Material damage Tire repair spray damages the tire pressure sensor. – Note that after using tire repair spray, the tire pressure sensor may need to be replaced.

  • Page 93: Electrical System 16

    Make sure that the daytime running light is deacti- vated with the diagnostics tool when the menu item is not available, but the low beam is required. (Your authorized KTM workshop will be glad to help.) – Note the legal regulations regarding the daytime run- ning light.

  • Page 94: Installing The 12-V Battery

    16 ELECTRICAL SYSTEM Main work – Disconnect negative cable from the 12-V battery. – Remove positive terminal cover V01203-11 – Disconnect positive cable from the 12-V battery. – Take negative cable out of holders on the battery support bracket. – Remove screw –...

  • Page 95: Charging The 12-V Battery

    ELECTRICAL SYSTEM 16 – Hook negative cable into the holders on the battery support bracket. – Mount positive terminal cover – Connect negative cable to the 12 V battery. Guideline Screw, battery termi- M6x12 4.5 Nm (3.32 lbf ft) V01203-10 Finishing work –...
  • Page 96 16 ELECTRICAL SYSTEM Preparatory work – Remove the passenger seat. ( p. 68) Main work – Disconnect negative cable from the 12 V battery to avoid damaging the onboard electronics. – Remove positive terminal cover V01203-11 – Connect a battery charger to the 12-V battery. Connect the battery charger to the mains connection.

  • Page 97: Changing The Main Fuse

    ELECTRICAL SYSTEM 16 16.5 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all electrical power consumers of the vehicle. The main fuse is under the passen- ger seat.

  • Page 98: Changing The Abs Fuses

    16 ELECTRICAL SYSTEM 16.6 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS.

  • Page 99: Changing The Fuses Of Individual Electrical Power Consumers

    ELECTRICAL SYSTEM 16 16.7 Changing the fuses of individual electrical power consumers Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The fuse box containing the fuses of individual electrical power consumers is located under the seat. Preparatory work –...

  • Page 100: Loosening The Headlight Mask With The Headlight

    16 ELECTRICAL SYSTEM Put a spare fuse in the fuse box so that it is available if needed. – Check the function of the electrical power consumer. – Close the fuse box cover. Finishing work – Mount the passenger seat. ( p.

  • Page 101: Removing The Cover Of The Headlight Mask Rack

    ELECTRICAL SYSTEM 16 – Mount adjusting screw V01212-11 Finishing work – Check the headlight setting. ( p. 100) 16.10 Removing the cover of the headlight mask rack Info The cover of the headlight mask rack must be removed in order to gain access to the ACC1 and ACC2 power supply.

  • Page 102: Installing The Cover Of The Headlight Mask Rack

    16 ELECTRICAL SYSTEM 16.11 Installing the cover of the headlight mask rack Main work – Position cover by guiding the plug-in connector of the head- light through the opening. – Hold turn signal in the area and carefully press against the direction of travel, while pressing the cover tight at the same time.

  • Page 103: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 16 The light-dark boundary must be exactly on the lower mark- ing when the motorcycle is ready to be operated 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 104: Front Acc1 And Acc2

    16 ELECTRICAL SYSTEM 16.15 Front ACC1 and ACC2 Installation location – Power supplies ACC1 and ACC2 front are located under the cover of the headlight mask rack. V01216-10 16.16 ACC1 and ACC2 rear Installation location – The rear power supplies ACC1 and ACC2 are located under the passenger seat next to the battery compartment.

  • Page 105: Cooling System 17

    COOLING SYSTEM 17 17.1 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 106: Checking The Coolant Level In The Compensating Tank

    17 COOLING SYSTEM Main work – Remove radiator cap and cap of the compensating tank. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … Antifreeze −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: A00956-10 –...

  • Page 107: Draining The Coolant

    COOLING SYSTEM 17 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 108: Filling/Bleeding The Cooling System

    17 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 109: Changing The Coolant

    COOLING SYSTEM 17 – Remove bleeder screw – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw immedi- ately. Coolant 1.6 l (1.7 qt.) Coolant ( p.
  • Page 110 17 COOLING SYSTEM – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw with the seal ring. V01254-11 – Remove radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw plug, EJOTALtracs...

  • Page 111: Tuning The Engine 18

    TUNING THE ENGINE 18 18.1 Ride Mode Possible states SPORT – Homologated performance with very direct response; • the motorcycle traction control allows greater slip on the rear wheel. STREET – Homologated performance with balanced response; • the motorcycle traction control allows normal slip on the rear wheel.

  • Page 112: Slip Adjustment (Optional)

    18 TUNING THE ENGINE 18.3 Slip adjustment (optional) The spin adjuster is a motorcycle traction control function. The slip adjustment allows the motorcycle traction control to be tuned through nine levels to the desired characteristic map. Level 1 allows the maximum slip on the rear wheel, and level 9 the minimum.

  • Page 113: Service Work On The Engine 19

    SERVICE WORK ON THE ENGINE 19 19.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 114 19 SERVICE WORK ON THE ENGINE – Remove oil drain plugs along with the magnets, the O- rings, and the oil screens. V01235-10 – Remove screws . Take off oil filter cover with the O- ring. – Pull oil filter out of the oil filter housing.

  • Page 115: Adding Engine Oil

    132) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. H01066-10 KTM recommends changing the engine oil where neces- sary. – Mount and tighten filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 116: Checking The Free Travel Of The Clutch Lever

    19 SERVICE WORK ON THE ENGINE 19.4 Checking the free travel of the clutch lever 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 117: Cleaning, Care 20

    CLEANING, CARE 20 20.1 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 118: Checks And Maintenance Steps For Winter Operation

    20 CLEANING, CARE – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 70) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 119: Storage 21

    – 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. 66) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 120: Preparing For Use After Storage

    21 STORAGE 21.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 67) – Remove the rear of the motorcycle from the lifting gear. p. 66) – Charge the 12-V battery. p. 93) –...

  • Page 121: Troubleshooting 22

    Join quick release coupling. joined – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Throttle opened while starting When starting, DO NOT open the throt- tle. – Carry out start procedure. ( p.
  • Page 122 – 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 123: Technical Data 23

    TECHNICAL DATA 23 23.1 Engine Design 2-cylinder 4-stroke in-line engine, water-cooled Displacement 890 cm³ (54.31 cu in) Stroke 68.8 mm (2.709 in) Bore 90.7 mm (3.571 in) Compression ratio 13.5:1 Control DOHC, 4 valves per cylinder controlled via cam lever, chain drive Valve diameter, intake 37 mm (1.46 in)

  • Page 124: Engine Tightening Torques

    23 TECHNICAL DATA 23.2 Engine tightening torques EJOTALtracs Plus 60x14 Screw plug, water pump drain hole ® 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, bleeder flange EJOTALtracs ® M6x12 8 Nm (5.9 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Nozzle, engine vent 2 Nm (1.5 lbf ft)
  • Page 125 TECHNICAL DATA 23 Screw, main shaft bearing support 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil pan M6x30 10 Nm (7.4 lbf ft) Screw, oil pan M6x35 10 Nm (7.4 lbf ft) Screw, oil pump cover 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 126: Capacities

    23 TECHNICAL DATA Screw, conrod bearing M8x0.75 1st stage 5 Nm (3.7 lbf ft) 2nd stage 20 Nm (14.8 lbf ft) 3rd stage 90° Screw support and thread oiled Spark plug 11 Nm (8.1 lbf ft) Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) Screw plug, bearing support M10x1...

  • Page 127: Fuel

    TECHNICAL DATA 23 23.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Fuel tank capacity, approx. 14 l (3.7 US gal) Super unleaded (ROZ 95) p. 133) 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tub- ing, powder-coated WP APEX 3043 Fork...

  • Page 128: Electrical System

    120/70 ZR 17 M/C (58W) TL (J) 180/55 ZR 17 M/C (73W) TL (G) Continental ContiRoad Continental ContiRoad The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: KTM.COM 23.7 Fork Fork article number 0636C126U201102 Fork...

  • Page 129: Chassis Tightening Torques

    TECHNICAL DATA 23 Medium (standard) 140 … 185 N/mm (799 … 1,056 lb/in) Gas pressure 16 bar (232 psi) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 133) 23.9 Chassis tightening torques Radiator hose hose clamp 2.2 Nm (1.62 lbf ft) Remaining screws, chassis EJOTPT ®...
  • Page 130 23 TECHNICAL DATA Nut, shift rod 6 Nm (4.4 lbf ft) Nut, shift rod M6LH 6 Nm (4.4 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, activated carbon filter 6 Nm (4.4 lbf ft) holder Screw, angle sensor...
  • Page 131 TECHNICAL DATA 23 Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ Pin, rear brake caliper 22 Nm (16.2 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp 12 Nm (8.9 lbf ft) Screw, cross member...
  • Page 132 23 TECHNICAL DATA Screw, subframe brace 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, top triple clamp 15 Nm (11.1 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Loctite ® 243™ Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, front footrest bracket...

  • Page 133: Declarations Of Conformity 24

    Declaration of Conformity is available at the following Internet address. Certification website: http://www.ktm.com/btrouter KTM AG hereby declares that the Immo641 wireless system conforms with the relevant guidelines. The full text of the Declaration of Conformity is available at the following Internet address.

  • Page 134: 25 Substances

    25 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 135 SUBSTANCES 25 Fork oil (SAE 5) Standard/classification – SAE ( p. 135) (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 136: 26 Auxiliary Substances

    26 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 137: Standards 27

    STANDARDS 27 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 138: 28 Index Of Special Terms

    Auxiliary function of the engine control, which pre- vents rear wheel locking with excessive engine braking effect, by lightly opening the throttle valve KTM MY RIDE System for wireless communication with appropriate cellphones and headsets for telephony and audio Launch control...

  • Page 139: List Of Abbreviations 29

    LIST OF ABBREVIATIONS 29 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 140: 30 List Of Symbols

    109) is not enabled or is currently interven- ing. The TC indicator lamp also lights up if a malfunction is detected. Contact an authorized KTM workshop. The TC indicator lamp flashes if MTC actively engages or if the Launch Control p. 54) is activated.

  • Page 141: Index

    ......76 KTM MY RIDE ..... . . 42 Brake fluid Language .
  • Page 142 INDEX Trip 2 ......31 Front rider’s seat warnings ..... . . 24, 38 mounting .
  • Page 143 INDEX Motorcycle Shift lever ......21 cleaning ......115 basic position, adjusting .
  • Page 144 INDEX View of vehicle front left ......11 rear right ......12 Winter operation checks and maintenance steps .
  • Page 145 *3214542en* 3214542en 01/2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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