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TROUBLE
Engine overheats
High oil consumption
Electric
system
not
operational
All switched on lamps blown
out
Headlight and parking light
fail
Flasher lights, brake light,
fan and horn fail
The NEUTRAL lamp is not
on even though the gear is
in NEUTRAL
The battery is discharged
No values are visible in the
Tripmaster display.
No speed display.
CAUSE
Insufficient cooling liquid
Radiator fins are extremely dirty
Foam forms in cooling system
Bent radiator hose
Thermostat defective
Blown fan fuse
Defect thermoswitch
Fan defective
Buckling gear ventilation hose
Engine oil level too high
Engine oil too thin (viscosity)
Blown main fuse.
Discharged battery.
Voltage regulator faulty
Blown fuse
Blown fuse
Defect neutral switch.
Loose connections, defect cable.
The ignition (power consumer)
hasn't been switched off
The battery isn't charged by the
generator because
Main fuse melted through
Defective sensor cable or oxidized
socket connector.
REMEDY
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Clean radiator with water jet
Replace cooling liquid, use antifreezer with brand name
Shorten or replace cooling hose
Remove and check thermostat (opening temperature 70°C
(158°F) or replace it, contact a KTM dealer
Replace fuse and check if fan operates properly (see below)
Contact a KTM dealer
Check if fan operates properly. To do this, start the engine,
then bypass the connections to the thermoswitch (bottom
right radiator), contact a KTM dealer
Readjust or replace ventilation hose
Check engine oil level when the engine is warm; correct if
necessary
Use thicker engine oil; see chapter „Engine oil"
Remove seat and replace the main fuse. If fuse blows again
contact a KTM dealer.
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer.
Remove seat and check connections. Have voltage regulator
checked
Replace fuse (5).
Replace fuse (4).
Connect cable to ground; neutral switch must be replaced if
indicator lamp lights up.
Check connections and cables.
Recharge the battery according to the relevant instructions.
Remove seat and check voltage regulator connections; voltage
regulator and generator should be checked by a KTM dealer.
Replace the main fuse (1) under the seat
Check the sensor cable for damage and replace it if necessary.
Remove the headlight mask and check the socket connector.
Contact a KTM dealer.
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