Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for KTM 2015 450 Rally Factory Replica
Summary of Contents for KTM 2015 450 Rally Factory Replica
- Page 1 OWNER'S MANUAL 2015 450 Rally Factory Replica Art. no. 3213181en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.
-
Page 4: Table Of Contents
TABLE OF CONTENTS 7.10 Setting the unit of measurement ...... 23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 7.11 Display mode SPEED/CLK (time) ...... 23 Symbols used ........... 5 7.12 Setting the clock..........24 Formats used............ 5 7.13 Display mode SPEED/LAP (lap time)....24 SAFETY ADVICE............ - Page 5 TABLE OF CONTENTS 12.9 Checking the steering head bearing play.... 49 14.4 Installing the rear wheel ....... 80 12.10 Adjusting the play of the steering head 14.5 Checking the rear hub rubber dampers ..81 bearing ............50 14.6 Checking the tire condition ......81 12.11 Greasing the steering head bearing ....
- Page 6 TABLE OF CONTENTS 26 AUXILIARY SUBSTANCES ........125 27 STANDARDS ............127 INDEX ................128...
-
Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left L02700-10 Clutch lever ( p. 13) Seat release strap Shift lever ( p. 17) Side stand ( p. 18) -
Page 12: View Of Vehicle, Rear Right
VIEW OF VEHICLE View of vehicle, rear right L02701-10 Kill switch ( p. 13) Light switch ( p. 13) Turn signal switch ( p. 14) Horn button ( p. 14) Fuel pump switch ( p. 15) Electric starter button ( p. -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number Chassis number is embossed in the steering head at the right. 401945-10 Type label Type label is fixed to the right of the steering head. 402399-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. -
Page 14: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number Shock absorber article number is located on the bottom of the shock absorber com- pensating tank. 0 0 1 401948-10... -
Page 15: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. L02711-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake. -
Page 16: Turn Signal Switch
CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – Turn signal switch is in the central position. Turn signal, left, on – Turn signal switch turned to the left. Turn signal, right, on –... -
Page 17: Fuel Pump Switch
CONTROLS 6.10 Fuel pump switch The fuel pump switch is fitted on the left side of the handlebar. Possible states FRONT – In this position, the fuel pump of the two front fuel tanks is active. Only the front fuel tanks empty out. REAR –... -
Page 18: Closing The Filler Caps
CONTROLS – Turn filler caps counterclockwise and lift off. L02714-10 6.13 Closing the filler caps – Mount filler caps , and and turn clockwise until the fuel tanks are tightly closed. Info Route fuel tank breather hoses without kinks. -
Page 19: Idle Speed Adjusting Screw
CONTROLS 6.14 Idle speed adjusting screw Idle speed adjusting screw is located at the top left of the throttle valve body. The idle speed adjusting screw is only easily accessible when the left fuel tank is removed. The idle speed adjusting screw has two functions. Turning it controls the idle speed. -
Page 20: Side Stand
CONTROLS 6.17 Side stand The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. Info When you are riding, the side stand must be folded up and secured with the ... -
Page 21: Unlocking The Steering
CONTROLS 6.20 Unlocking the steering – Insert the key in the steering lock, turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. 400731-01... -
Page 22: Speedometer
SPEEDOMETER Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. -
Page 23: Setting The Speedometer Functions
SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. -
Page 24: Display Mode Speed (Speed)
SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –... -
Page 25: Setting The Unit Of Measurement
SPEEDOMETER Briefly press the Activates the flashing display and changes to the next display button Press the button No function for 2–3 seconds. Briefly press the Deactivates the flashing display and changes to the next dis- button play Press the button No function for 2–3 seconds. -
Page 26: Setting The Clock
SPEEDOMETER 7.12 Setting the clock Condition • The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. Press the button Increases the value for 2–3 seconds. -
Page 27: Display Mode Speed/Odo (Odometer)
SPEEDOMETER 7.15 Display mode SPEED/ODO (odometer) – Repeatedly press the button briefly until ODO appears at the bottom right of the display. The total traveled distance is shown in display mode ODO. Press the button No function for 2–3 seconds. Briefly press the Next display mode button... -
Page 28: Display Mode Speed/A1 (Average Speed 1)
SPEEDOMETER Info The TR2 value can also be corrected manually during the journey with the but- and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the button Increases value of TR2. for 2–3 seconds. Briefly press the Increases value of TR2. -
Page 29: Display Mode Speed/S1 (Stop Watch 1)
SPEEDOMETER 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the dis- play. S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor. -
Page 30: Table Of Conditions And Menu Activation
SPEEDOMETER Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The stop watch Next display Stops the clock. Starts the stop SPEED/LAP (lap and the lap time... -
Page 31: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 32: Running In The Engine
PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 400 kg (882 lb.) Maximum permissible front axle load 190 kg (419 lb.) Maximum permissible rear axle load 250 kg (551 lb.) -
Page 33: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. -
Page 34: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 35: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 36: Refueling
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 37: Service Schedule
Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● Make the service entry in KTM Dealer.net and in the service record. -
Page 38: Service Work (As Additional Order)
SERVICE SCHEDULE ○ One-time interval ● Periodic interval 10.2 Service work (as additional order) Annually after every race Every 100 operating hours Every 50 operating hours Every 40 operating hours Once after 20 operating hours ● ● Change the front brake fluid. ●... -
Page 39: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 41: Checking The Static Sag Of The Shock Absorber
TUNING THE CHASSIS Main work – Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover. – Note down the value as dimension 400988-10 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 42: Adjusting The Spring Preload Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 43: Checking The Basic Setting Of The Fork
TUNING THE CHASSIS Guideline Spring rate Weight of rider (soft): 65… 75 kg 51 N/mm (291 lb/in) (143… 165 lb.) Weight of rider (standard): 75… 54 N/mm (308 lb/in) 85 kg (165… 187 lb.) Weight of rider (hard): 85… 95 kg 57 N/mm (325 lb/in) (187…... -
Page 44: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. - Page 45 TUNING THE CHASSIS – Remove the four screws . Take off bracket – Take off handlebar clamps with rubber washers and elastomers – Fix the handlebar onto the instrument support with cable ties. Info Protect the motorcycle and its attachments against damage by covering them.
-
Page 46: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) The wheels must no longer touch the ground. -
Page 47: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) – Dismount the front fender. ( p. 54) Main work – Push dust boots of both fork legs downward. -
Page 48: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.6 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The upper triple clamp must be flush with the upper edge of the fork legs. L02728-10 –... -
Page 49: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS – Remove screws . Remove the holding plate with handlebar clamps. – Remove screws . Remove steering damper L02732-10 – Fix handlebar onto the instrument support with cable tie(s) L02733-10 –... - Page 50 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp. – Mount screw but do not tighten yet. L02734-11 – Position the fork legs. Bleeder screws are positioned toward the front. Info The fork legs must be flush with the upper edge of the upper triple clamp. L02736-10 –...
-
Page 51: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 52: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 12.10 Adjusting the play of the steering head bearing Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) Main work – Remove screws . Remove the holding plate with handlebar clamps. –... -
Page 53: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 12.11 Greasing the steering head bearing – Remove the lower triple clamp. p. 46) – Install the lower triple clamp. p. 47) 800010-10 12.12 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 54: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Place an object under the rear wheel to lift the swingarm. L02824-01 – Remove screws L02825-10 – Remove screw L02827-10 – Remove the shock absorber toward the top. L02826-01 12.13 Installing the shock absorber Main work –... - Page 55 SERVICE WORK ON THE CHASSIS – Mount and tighten screws L02829-10 – Remove the object under the rear wheel. L02824-10 – Mount and tighten screw cap Guideline Nut, linkage lever to angle lever M14x1.5 100 Nm (73.8 lbf ft) –...
-
Page 56: Dismounting The Front Fender
SERVICE WORK ON THE CHASSIS 12.14 Dismounting the front fender – Remove cable tie(s) L02787-10 – Remove screws . Remove front fender L02726-11 12.15 Installing the front fender – Position front fender . Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 57: Mounting The Seat
SERVICE WORK ON THE CHASSIS 12.17 Mounting the seat – Position the seat between the two front fuel tanks. – Insert locking pin into the lock housing and push down the rear of the seat until the locking pin engages with a click. –... -
Page 58: Installing The Air Filter
SERVICE WORK ON THE CHASSIS – Clean the air filter box. – Check the intake flange for damage and looseness. Finishing work – Install the air filter. p. 56) – Mount the seat. ( p. 55) 12.20 Installing the air filter Preparatory work –... -
Page 59: Changing The Glass Fiber Yarn Filling Of The Main Silencer
SERVICE WORK ON THE CHASSIS 12.23 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". -
Page 60: Removing The Front Right Fuel Tank
SERVICE WORK ON THE CHASSIS – Mount wash cap set from the separate enclosure. Wash cap set (81212016100) L02750-10 – Clean the plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve. -
Page 61: Installing The Front Left Fuel Tank
SERVICE WORK ON THE CHASSIS – Mount wash cap set from the separate enclosure. Wash cap set (81212016100) L02750-10 – Detach fuel tank breather hose – Remove screws – Take off the fuel tank. Info Set the fuel tank down in an upright position as otherwise fuel can escape from the fuel tank breather at the filler cap. -
Page 62: Installing The Front Right Fuel Tank
SERVICE WORK ON THE CHASSIS 12.27 Installing the front right fuel tank Main work – Position the fuel tank. Mount and tighten screws Guideline Screw, front fuel tank 8 Nm (5.9 lbf ft) – Mount fuel tank breather hose L02754-11 –... -
Page 63: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 125) Off-road chain spray ( p. 125) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 64: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 7 mm Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference ... - Page 65 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
-
Page 66: Checking The Frame
If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 601609-01 12.34 Checking the swingarm –... -
Page 67: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.36 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Grip adhesive (00062030051) ( p. -
Page 68: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 12.40 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 69: Mounting The Trim
SERVICE WORK ON THE CHASSIS – Unlock quick releases L02764-10 – Swing the trim forward and take it off. L02765-10 12.42 Mounting the trim – Position the trim on the opposite part of the radiator. – Swing the trim upward and hook into guides L02765-11 –... -
Page 70: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS – Connect plug-in connectors of the turn signals. L02763-11 12.43 Removing the engine guard – Remove screws . Take off the engine guard to the front. L02755-10 12.44 Installing the engine guard – Position the motor guard. -
Page 71: Brake System
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc ... -
Page 72: Checking The Front Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 73: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –... -
Page 74: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 75: Checking The Free Travel Of The Foot Brake Lever
BRAKE SYSTEM – Drive out pin with drift toward the rim and remove the brake linings. L02772-10 – Clean the brake caliper and brake caliper support. – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. -
Page 76: Adjusting The Free Travel Of The Foot Brake Lever
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 77: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 78: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 79 BRAKE SYSTEM – Drive out pin with drift toward the rim and remove the brake linings. L02778-10 – Clean the brake caliper and brake caliper support. – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly.
-
Page 80: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. -
Page 81: Removing The Rear Wheel
WHEELS, TIRES Info Ensure that the grip of the wheel spindle does not contact with the right fork leg. – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. – Remove the motorcycle from the lift stand. ( p. -
Page 82: Installing The Rear Wheel
WHEELS, TIRES – Remove the rear sprocket carrier L02786-10 14.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work –... -
Page 83: Checking The Rear Hub Rubber Dampers
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. -
Page 84: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 85 WHEELS, TIRES Torque wrench with various accessories in set (58429094000)
-
Page 86: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 87: Recharging The Battery
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Info Even when there is no load on the battery, it discharges steadily. -
Page 88: Changing Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM Main work – Remove protection cap – Remove the faulty main fuse L02794-10 – Fit a new main fuse. Fuse (58011109130) ( p. 105) Info Replace a faulty fuse by an equivalent fuse only. A reserve fuse is located in the starter relay. - Page 89 ELECTRICAL SYSTEM Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (58011109110) ( p.
-
Page 90: Cooling System
COOLING SYSTEM 16.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 91: Draining The Coolant
COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. 10 mm (0.39 in) Coolant level above the radiator fins. » If the coolant level does not meet specifications: –... -
Page 92: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3…... -
Page 93: Adjusting The Idle Speed
TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 2,000…... -
Page 94: Service Work On The Engine
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. Condition The engine is cold. – Check the engine oil level. Info After switching off the engine, wait a minute and then check. - Page 95 SERVICE WORK ON THE ENGINE – Remove screw plug with the long oil screen and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surfaces. L02811-10 – Mount and tighten screw plug with the short oil screen and the O-rings.
- Page 96 SERVICE WORK ON THE ENGINE – Lubricate the O-ring of the oil filter cover and mount it with the oil filter cover L02817-10 – Mount and tighten screws Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) L02815-10 –...
-
Page 97: Adding Engine Oil
SERVICE WORK ON THE ENGINE Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. – Install and tighten the oil filler plug with O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. -
Page 98: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 99: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you can expect salt on the roads. Precautions need to be taken against the aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 100: Storage
50… 75 % – Place the vehicle on a dry storage place that is not subject to large temperature variations. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 44) – Cover the vehicle with an air-permeable cover or blanket. -
Page 101: Troubleshooting
– Check the electrical system. – Defect in the fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in the fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 102 – Check the cabling for damage and the electri- cal plug-in connections for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.
-
Page 103: Blink Code
BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code of FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high... -
Page 104: Technical Data
TECHNICAL DATA 23.1 Motor Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 Idle speed 2,000… 2,200 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust... - Page 105 TECHNICAL DATA – Screw, alternator cover 10 Nm (7.4 lbf ft) Screw, bearing bolt for starter idler 10 Nm (7.4 lbf ft) Loctite ® 243™ gear Loctite 243™ Screw, bearing bolt, torque limiter 10 Nm (7.4 lbf ft) ® Screw, camshaft support plate 10 Nm (7.4 lbf ft) Loctite ®...
-
Page 106: Capacities
TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil Total filling level, oil 1.40 l (1.48 qt.) Engine oil (SAE 10W/50) ( p. 124) change Total filling level, engine 1.80 l (1.9 qt.) Engine oil (SAE 10W/50) ( p. 124) service (with oil radiator) 23.3.2 Coolant... -
Page 107: Electrical System
Rear tires 90/90 - 21 54S TT 130/80 - 18 66S TT Michelin T63 Michelin T63 Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.2N.40 WP Performance Systems Up Side Down 4860 MXMA CC... -
Page 108: Shock Absorber
TECHNICAL DATA 23.8 Shock absorber Shock absorber part number 18.18.0N.40 Shock absorber WP Performance Systems Compression damping, low-speed Standard 12 clicks Compression damping, high-speed Standard 34 clicks Rebound damping Standard 18 clicks Spring preload Standard 12 mm Spring rate Weight of rider (soft): 65… 75 kg (143… 165 lb.) 51 N/mm (291 lb/in) Weight of rider (standard): 75…... - Page 109 TECHNICAL DATA – Screw, cable on starter relay 5 Nm (3.7 lbf ft) Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, engine guard bracket on engine 15 Nm (11.1 lbf ft) bearer Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ®...
-
Page 110: Wiring Diagram
WIRING DIAGRAM 24.1 Page 1 of 8 bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd wh-rd , wh-rd br-pu , br br-pu , br br-pu , br bu-rd bu-rd bu-rd bu-rd bu-rd br-pu br-pu br-pu wh-gr wh-gr wh-gr L02802-10... - Page 111 WIRING DIAGRAM Components: Motor electronics control unit Battery Starter relay with main fuse Starter motor Electric starter button...
-
Page 112: 110
WIRING DIAGRAM 24.2 Page 2 of 8 wh-rd wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd wh-bl wh-rd wh-bl bl-gn ye-bu ye-bu L02803-10... - Page 113 WIRING DIAGRAM Components: Motor electronics control unit Radiator fan temperature switch F1.3 Fuse F1.6 Fuse F1.7 Fuse Alternator Power relay Radiator fan Voltage regulator...
-
Page 114: 112
WIRING DIAGRAM 24.3 Page 3 of 8 wh-gr wh-gr , wh-gr bu-or , bu-or gn-or gn-ye -X102 CC/12 bu-or CI/12 -X101 ye-bu wh-gn ye-bu wh-gn wh-gn wh-gn wh-gn wh-gn wh-gn wh-gn gn-ye wh-gn br , br L02804-10... - Page 115 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp F1.1 Fuse Horn Brake/tail light High beam Light switch, horn button, kill switch...
-
Page 116: 114
WIRING DIAGRAM 24.4 Page 4 of 8 bu-or gn-or gn-ye gn-ye -X103 -X103 BD/12 BD/12 AD/12 AD/12 -X104 -X104 gn-ye gn-ye bl-rd wh-rd gn-ye gn-ye gn-ye bl-rd bl-rd bl-rd gn-ye or-rd L02805-10... - Page 117 WIRING DIAGRAM Components: Low beam High beam F1.4 Fuse F1.5 Fuse High beam relay Low beam relay Parking light...
-
Page 118: 116
WIRING DIAGRAM 24.5 Page 5 of 8 wh-rd gn-rd gn-rd gn-rd gn-rd gn-rd gn-rd br , br , br L02806-10... - Page 119 WIRING DIAGRAM Components: F1.2 Fuse Turn signal relay Turn signal indicator light Front left turn signal Front right turn signal Rear left turn signal Rear right turn signal Speedometer Turn signal switch...
-
Page 120: 118
WIRING DIAGRAM 24.6 Page 6 of 8 bu-gr bu-gr pu-gn bu-gr bu-gn bu-gn bl-bu , bl-bu bl-bu br-rd bl-bu br-rd pu-gn bl-pu , bl-pu bl-pu rd-pu bl-pu rd-pu L02807-10... - Page 121 WIRING DIAGRAM Components: Motor electronics control unit F1.8 Fuse Relay for rear fuel pump Relay for front fuel pump Rear fuel pump Front fuel pump Low fuel warning lamp for rear fuel tank Low fuel warning lamp for front fuel tank Fuel pump switch...
-
Page 122: 120
WIRING DIAGRAM 24.7 Page 7 of 8 wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu bl-gr bl-br bl-br bl-gr gn-gr gn-gr gn-gr ye-bu gn-gr L02808-10... - Page 123 WIRING DIAGRAM Components: Motor electronics control unit Oil pressure sensor Injector Oil pressure warning lamp CAN bus terminating resistor...
-
Page 124: 122
WIRING DIAGRAM 24.8 Page 8 of 8 bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or gn-ye gn-ye L02809-10... - Page 125 WIRING DIAGRAM Components: Motor electronics control unit Accelerator position sensor Intake air temperature sensor Engine coolant temperature sensor Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor Ignition coil Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...
-
Page 126: Substances
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 corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... -
Page 127: Auxiliary Substances
Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ®... - Page 128 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
-
Page 129: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 130: Index
INDEX Compression damping, high-speed INDEX shock absorber, adjusting ..... 38 Accessories ........8 Compression damping, low-speed shock absorber, adjusting . - Page 131 INDEX Fuel pump switch ......15 Fuel tank ........15 Rear hub rubber dampers Fuse checking .
- Page 132 INDEX Swingarm checking ....... . . 64 Technical data capacities ....... 104 chassis .
- Page 133 *3213181en* 3213181en 12/2014 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...