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2015 OWNER'S MANUAL 200 Duke 2015 CO Art. no. 3213118en...
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KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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DEAR KTM CUSTOMER ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...
TABLE OF CONTENTS Hand brake lever..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Throttle grip ............23 Symbols used ............7 Horn button............23 Formats used............7 Light switch ............24 SAFETY ADVICE.............. 8 High beam flasher button ........24 Use definition............
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TABLE OF CONTENTS 6.11.18 Distance menu 1 TRIP 1 ........ 44 SERVICE SCHEDULE ............ 70 6.11.19 Distance menu 2 TRIP 2 ........ 45 Service schedule..........70 6.11.20 Setting kilometers or miles ......45 10 TUNING THE CHASSIS ..........72 6.11.21 Setting the time..........
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TABLE OF CONTENTS 15.3 Checking the coolant level ........ 131 12.3 Adding front brake fluid ......... 92 12.4 Checking the front brake linings ......94 15.4 Draining the coolant ........133 12.5 Checking the free travel of foot brake lever ... 95 15.5 Filling/bleeding the cooling system ....
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 optimally cared for by specially trained experts using the specialist tools required.
SAFETY ADVICE Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.
SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. 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.
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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.
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.
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 considered for damage resulting from manipulations and/or alterations to the vehicle.
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. A list of authorized KTM dealers can be found on the KTM website.
VIEW OF VEHICLE View of vehicle, front left (example) B00778-10...
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VIEW OF VEHICLE Function buttons ( p. 32) Indicator lamps ( p. 33) Rear mirror Clutch lever ( p. 22) Seat Passenger seat Seat lock ( p. 50) Grab handles ( p. 51) Engine number ( p. 20) Side stand ( p.
VIEW OF VEHICLE View of vehicle, rear right (example) B00779-10...
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VIEW OF VEHICLE Tool set ( p. 51) Light switch ( p. 24) High beam flasher button ( p. 24) Turn signal switch ( p. 25) Horn button ( p. 23) Filler cap Ignition/steering lock ( p. 26) Emergency OFF switch ( p.
SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the right of the steering head. The type label is on the right of the frame behind the steering head. B00699-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.
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. B00755-10...
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. M00001-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. B00702-10...
CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. B00703-10 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed –...
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and the tail light are switched on.
CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal, right, on –...
CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button B00708-10 6.10 Ignition/steering lock...
CONTROLS 6.11 Combination instrument 6.11.1 Overview Display ( p. 34) Function buttons ( p. 32) Info display ( p. 38) Indicator lamps ( p. 33) 401685-10...
CONTROLS 6.11.2 Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up briefly.
CONTROLS 6.11.3 Warning notes Low Oil Pressure appears on the info display if the oil pressure is too low. 401309-01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark. 401310-01...
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CONTROLS High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 125 °C (257 °F) 401311-01 Side Stand Down appears on the info display if the side stand is folded down. 401312-01 Low Battery appears on the info display if the battery voltage falls below the specified value.
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CONTROLS Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment. 401461-01...
CONTROLS 6.11.4 Function buttons You can change the display mode with the MODE button Possible display modes are total distance traveled (TRIP 1), distance 1 (ODO) and distance 2 (TRIP 2). Pressing and holding the SET button resets the distance 1 (TRIP 1) and ...
CONTROLS 6.11.5 Indicator lamps Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The engine diagnosis warning lamp (MIL) lights up red – The OBD (on- board diagnosis) has detected an emission- or safety-critical error. The shift warning lights up/flashes red –...
CONTROLS 6.11.6 Display The speed is shown in kilometers per hour km/h or in miles per hour mph. The tachometer shows the engine speed in revolutions per minute. The gear display shows the engaged gear. The coolant temperature appears in segment ...
CONTROLS 6.11.7 Filling level display in fuel tank The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank. 401292-01...
CONTROLS 6.11.8 TRIP F display If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note Low Fuel Level appears on the info display.
CONTROLS 6.11.9 Coolant temperature indicator The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Coolant Temperature. Possible states Engine cold –...
CONTROLS 6.11.10 Info display Various warning notes appear on info display If the general warning lamp lights up, the corresponding warning note is shown on the info display. 401291-10...
CONTROLS 6.11.11 Riding time/average speed menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed in this menu.
CONTROLS Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on. If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0. Press the SET button Next display mode on the info display briefly.
CONTROLS 6.11.14 Average fuel consumption 2/service menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The average fuel consumption 2 in km/L (or miles/L) and the distance to the next service 401467-01 are displayed in this menu.
CONTROLS 6.11.15 Service/range menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next service and the range.
CONTROLS 6.11.16 Range/riding time menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displayed in this menu.
CONTROLS 6.11.17 Total distance menu ODO Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered.
CONTROLS Press the SET button Display of TRIP 1 is reset for 5 - 10 seconds. Press the MODE but- Next display mode on the display ton. 6.11.19 Distance menu 2 TRIP 2 Condition Alternative 1 • The ignition is on. •...
CONTROLS The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE button for 5 - 10 seconds. The display changes from km/h to mph or from mph to km/h. 401303-01 6.11.21 Setting the time Condition...
CONTROLS 6.11.22 Adjusting the shift speed RPM 1 Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the MODE button for 5 - 10 seconds. The display RPM 1 appears.
CONTROLS – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the SET button for 5 - 10 seconds. The display RPM 2 appears. Info The engine speed can be set at intervals of 50. RPM 2 is the engine speed above which the shift warning light lights up con- stantly.
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CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
CONTROLS 6.13 Closing the filler cap Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.
CONTROLS 6.15 Tool set The tool set is located under the passenger seat. B00758-10 6.16 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. B00717-10...
CONTROLS 6.17 Passenger footrests The passenger footrests can be folded in and out. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • B00713-01 6.18 Shift lever ...
CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. B00716-10 6.19 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. B00718-10...
CONTROLS 6.20 Side stand The side stand is on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –...
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...
PREPARING FOR USE – 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. – Before your first trip, read the entire operating instructions carefully.
PREPARING FOR USE Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
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PREPARING FOR USE – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.)
RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.
RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
RIDING INSTRUCTIONS – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position After you switch on the ignition, you can hear the fuel pump working for about two seconds.
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, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –...
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If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
Clean or dry a dirty or wet brake system by riding and braking gently. Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
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RIDING INSTRUCTIONS Warning Danger of accidents Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking. Warning Danger of accidents Longer stopping distance due to higher overall weight.
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. If you leave the vehicle, lock the steering and remove the ignition key. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.
RIDING INSTRUCTIONS – Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine with the ignition key - the emergency OFF switch is intended for emergencies only.
Material damage Premature clogging of the fuel filter. – 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.)
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RIDING INSTRUCTIONS – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. –...
○ ● ● Check the functioning of the electrical equipment. ○ ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● Change the engine oil and oil filter, clean the oil screen. p. 139) ○...
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Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in KTM DEALER.NET and in the service record.
TUNING THE CHASSIS 10.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial situation of the spring process on the shock absorber.
TUNING THE CHASSIS 10.2 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 100… 112 mm (3.94… 4.41 in) Shift rod adjustment range Info Make the same adjustments on both sides.
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the supports of the wheel stand. –...
SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand – Remove the support of the wheel stand. B00714-10 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over.
SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem. Adapter (61029955620) Front wheel stand (61029055500) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. C00197-01 11.4 Taking the motorcycle off of the front wheel stand...
SERVICE WORK ON THE CHASSIS – Mount cap M00005-10 11.5 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards. –...
SERVICE WORK ON THE CHASSIS 11.6 Mounting the passenger seat – Attach hooks on the passenger seat to brackets on the subframe, and lower it at the rear while pushing forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.
SERVICE WORK ON THE CHASSIS 11.8 Mounting the seat Main work – Attach seat recesses at screws and lower at the rear. – Mount and tighten screws Guideline Screw, seat 11 Nm (8.1 lbf ft) B00727-10 Finishing work –...
SERVICE WORK ON THE CHASSIS 11.9 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 80) 400678-01 11.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...
SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.
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SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. – In the area of chain sliding guard, press the chain upward toward the swingarm and determine chain tension Info The upper chain section must be taut.
SERVICE WORK ON THE CHASSIS 11.12 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.
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SERVICE WORK ON THE CHASSIS Main work (Option: Without ABS) – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) ...
SERVICE WORK ON THE CHASSIS 11.13 Checking the chain, rear sprocket, and engine sprocket (Option: Without ABS) – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
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SERVICE WORK ON THE CHASSIS – Shift gear to neutral. – Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 20 chain links in the lower chain section. Info 0 0 A Chain wear is not always even, so you should repeat this measurement at...
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SERVICE WORK ON THE CHASSIS – Remove screws and release screw . Push the chain guard aside. C00198-10 – Check the chain sliding guard for wear. » If the chain sliding guard has lost material due to wear to the extent that, in area ...
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SERVICE WORK ON THE CHASSIS – Position the chain guard and tighten screw Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Tighten screw Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) –...
SERVICE WORK ON THE CHASSIS 11.15 Fitting front spoiler – Position the front spoiler. Mount screws but do not tighten yet. B00770-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Tighten screw ...
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
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.
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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.
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. –...
BRAKE SYSTEM 12.5 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.
BRAKE SYSTEM 12.6 Adjusting the free travel of the foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.
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.) (Option: Without ABS) –...
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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.
Checking the rear 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. –...
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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. »...
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 74) – Raise the motorcycle with the front wheel stand. ( p. 75) Main work (Option: Without ABS) – ...
WHEELS, TIRES Info Do not pull the hand brake lever when the front wheel is removed. 13.2 Installing the front 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.
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WHEELS, TIRES Main work (Option: Without ABS) – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers.
WHEELS, TIRES 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 74) Main work (Option: Without ABS) – Remove nut and the washer. Remove chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster ...
WHEELS, TIRES 13.4 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. Warning Danger of accidents No braking effect when operating the rear brake.
WHEELS, TIRES – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Info Mount the left and right chain adjusters in the same position. – Mount nut and washer. – Push the rear wheel forward so that the chain adjusters are on the screws, and ...
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WHEELS, TIRES Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 74) – Remove the rear wheel. p. 104) Main work – Check bearing » If the bearing is damaged or worn: – Change the bearing. –...
Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.
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WHEELS, TIRES » If the tire air pressure does not meet specifications: – Correct the tire air pressure. – Mount the dust cap.
ELECTRICAL SYSTEM 14.1 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. –...
ELECTRICAL SYSTEM – Pull back the positive terminal cover – Disconnect the positive cable of the battery. – Detach rubber band – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged.
ELECTRICAL SYSTEM – Connect the negative cable of the battery. – Position the negative terminal cover B00750-11 Finishing work – Mount the seat. ( p. 79) – Mount the passenger seat. ( p. 78) – Set the clock. ( p.
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– Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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 still loses power steadily.
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ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info ...
ELECTRICAL SYSTEM 14.4 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 passenger seat. Preparatory work – Switch off all power consumers and switch off the engine. –...
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ELECTRICAL SYSTEM Info A defective fuse is indicated by a burned-out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
ELECTRICAL SYSTEM 14.5 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Preparatory work –...
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ELECTRICAL SYSTEM – Take off protection cap – Disconnect plug-in connector B00760-10 – Detach retaining clamp – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Headlight (H4/socket P43t) ( p. 158) Info Insert the headlight bulb so that the catches latch into the recesses.
ELECTRICAL SYSTEM – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm (8.1 lbf ft) 601914-10 – Mount expanding rivets on both sides. – Check that the lighting is functioning properly. 601915-10 14.6 Changing the parking light bulb...
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ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. Main work – Remove expanding rivets 601915-10 – Remove screws – Lift the headlight mask slightly and swing forward. 307324-10...
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ELECTRICAL SYSTEM – Remove screws – Take off cover B00762-10 – Pull the socket with bulb out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9.5d) ( p.
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ELECTRICAL SYSTEM – Position cover – Mount and tighten screws B00762-10 – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm (8.1 lbf ft) 307324-10 – Mount expanding rivets on both sides.
ELECTRICAL SYSTEM 14.7 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...
ELECTRICAL SYSTEM 14.8 Adjusting the headlight range Main work – Remove expanding rivets 601915-10 – Remove screws – Lift the headlight mask slightly and swing forward. 601914-10...
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ELECTRICAL SYSTEM – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking headlight adjustment).
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ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 124)
COOLING SYSTEM 15.1 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 . Heat expansion causes excess coolant to flow into compensating tank When the temperature falls, this surplus coolant is sucked back into the cooling system.
COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 401768-10 15.2 Checking the antifreeze and coolant level...
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COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately.
COOLING SYSTEM – Remove radiator cap – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled.
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COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately.
COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 164) » If you had to add more coolant than the specified amount: > 0.20 l (> 0.21 qt.) – Fill/bleed the cooling system. p. 134) – Mount the radiator cap. 15.4 Draining the coolant Warning...
COOLING SYSTEM Main work – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw – Remove the radiator cap. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline B00768-10 Plug, water pump drain hole...
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COOLING SYSTEM – Open bleeder screw by three 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 immediately. Alternative 1 Coolant ( p.
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth to ascertain play in the throttle cable. Throttle cable play 3…...
TUNING THE ENGINE 16.2 Adjusting the play in the throttle cable – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the throttle cable by turning adjusting screw Guideline Throttle cable play 3…...
TUNING THE ENGINE » If the clutch lever play changes: – Check the routing of the clutch cable. 16.4 Adjusting the clutch cable play – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut ...
SERVICE WORK ON THE ENGINE 17.1 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. The engine oil must be between the lower and upper edge of the oil level viewer.
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SERVICE WORK ON THE ENGINE Info Drain the engine oil only when the engine is warm. Preparatory work – Remove the front spoiler. ( p. 89) – Stand the motorcycle on its side stand on a horizontal surface. Main work –...
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SERVICE WORK ON THE ENGINE – Insert oil filter – Oil the O-ring of the oil filter cover. Mount oil filter cover – Mount and tighten the screws. Guideline Screw, oil filter cover 8 Nm (5.9 lbf ft) Info Too little engine oil or poor-quality engine oil results in premature wear to the B00776-10...
SERVICE WORK ON THE ENGINE Finishing work – Fit the front spoiler. ( p. 90) – Check the engine oil level. ( p. 139) 17.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work –...
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SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight. Finishing work – Check the engine oil level. ( p. 139)
CLEANING, CARE 18.1 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 pres- sure can cause malfunctions or destroy these parts.
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CLEANING, CARE Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.
CLEANING, CARE Perfect Finish and high gloss polish for paints ( p. 168) Info Do not polish parts that were matte when delivered as this would strongly impair the material quality. – 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.
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CLEANING, CARE – Treat the engine, swingarm, and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor. Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force. –...
113) Guideline Storage temperature of battery without 0… 35 °C (32… 95 °F) direct sunlight – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle.
STORAGE – Raise the motorcycle with the rear wheel stand. ( p. 74) – Raise the motorcycle with the front wheel stand. ( p. 75) – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Operating error Go through the steps of starting the engine. p. 60) – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter is very dirty Change the air filter.
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Defect in radiator fan system Check the radiator fan system. – The engine diagnosis warning Defect in fuel injection system Read out the fault memory using the KTM diag- lamp (MIL) lights up red nostics tool. – Engine dies during the trip Lack of fuel Refuel.
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TROUBLESHOOTING Faults Possible cause Action – Speedometer in combination instru- Speedometer wiring harness is dam- Check the wiring harness and plug-in connection. ment not functioning aged or plug-in connection is oxidized...
TECHNICAL DATA Tire air pressure with passenger/full payload Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Secondary ratio 14:42 Chain 5/8 x 1/4” (520) O‑ring Steering head angle 65° Wheelbase 1,367±15 mm (53.82±0.59 in) Seat height, unloaded 810 mm (31.89 in) Ground clearance, unloaded 170 mm (6.69 in) Weight without fuel, approx.
Front tires Rear tires 110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork Fork part number 90101000044 Fork WP Suspension Fork length 736 mm (28.98 in)
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 possesses the correspond- ing properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
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SUBSTANCES Engine oil (SAE 15W/50) Standard/classification – JASO T903 MA ( p. 169) – SAE ( p. 169) (SAE 15W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
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SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 169) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper- ties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
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AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine 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 ®...
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 specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.