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DEAR KTM CUSTOMER We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcy- DEAR KTM CUSTOMER cle that will give you a great deal of pleasure during your ownership if you service and maintained it accordingly.
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Reproduction, even in part, is permitted only with the express written permission of the copyright owner. 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.
TABLE OF CONTENTS Setting the clock .............. 28 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........6 Combination instrument - display ODO ....... 29 IMPORTANT INFORMATION ........... 7 Combination instrument - setting/resetting TRIP 1....29 VIEW OF VEHICLE..............12 Combination instrument - setting/resetting TRIP 2....30 View of vehicle, front left side..........
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............ 78 Important maintenance work to be carried out by an Installing the rear wheel ..........79 authorized KTM workshop. (as additional order)....55 Checking the rear hub rubber dampers ......81 MAINTENANCE WORK ON FRAME AND ENGINE....57 Checking the tire condition..........82 Jacking up front of motorcycle ...........
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TABLE OF CONTENTS Adjusting basic position of clutch lever......109 TECHNICAL DATA - CHASSIS ..........141 Checking the basic position of the shift lever..... 110 Lighting equipment ............142 Capacity - fuel..............143 Adjusting the basic position of the shift lever ....
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth- erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
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Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
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IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons.
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IMPORTANT INFORMATION Grades of risks 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 will possibly lead to light injury if the appropriate measures are not taken.
VIEW OF VEHICLE View of vehicle, front left side 600882-10...
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VIEW OF VEHICLE Combination instrument Rear mirror Clutch lever Seat Handrail Front brake caliper Left fuel tap Shift lever Engine number Side stand...
VIEW OF VEHICLE View of vehicle, rear right 600881-10...
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VIEW OF VEHICLE Seat lock Light switch, headlight flasher switch, turn signal switch, horn Filler cap Emergency OFF switch, electric starter button Hand brake lever Chassis number, type label Brake caliper, rear Passenger footrests Foot brake lever Level viewer, engine oil Right fuel tap...
LOCATION OF 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. 500006-01 Key number The key number can be found on the KEYCODECARD.
LOCATION OF SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 500001-01 Fork part number The fork part number is stamped on the inner side of the fork stub. ...
LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 100185-10...
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 100113-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. ...
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upwards. 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 Left turn signal on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use. Right turn signal on –...
CONTROLS Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.
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 500022-11 Combination instrument 5.10...
CONTROLS Combination instrument - function buttons 5.11 You can change the display mode with the MODE button Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas- ter 2 (TRIP 2). Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- ...
CONTROLS Combination instrument - indicator lamps 5.13 The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idle speed indicator lamp lights up green –...
CONTROLS Combination instrument - display 5.14 When you switch on the ignition, all display segments light up for one second as a function test. 700118-01 LEnGth Following the display function test, the LEnGth wheel circumference is shown for one sec- ond.
CONTROLS Combination instrument - speedometer 5.15 The speed is shown in kilometers per hour km/h or in miles per hour mph. 700114-01 Setting kilometers or miles 5.16 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country.
CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.
CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –...
CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 700121-01 Combination instrument - setting/resetting TRIP 2 5.21...
CONTROLS Combination instrument - TRIP F display 5.22 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info Parallel to the TRIP F display, the fuel warning light switches on. 700123-01 Combination instrument - coolant temperature indicator 5.23...
CONTROLS Opening filler cap 5.24 – Lift the cover of the filler cap and insert the ignition key. – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 500023-10 Closing filler cap 5.25...
CONTROLS Fuel taps 5.26 The fuel taps are located on the left/right under the fuel tank. Possible states Fuel supply closed – The knurled screws are turned clockwise as far as possible. The • level cannot be compensated and no fuel can flow out of the fuel tank. Fuel tap open –...
CONTROLS Seat lock 5.28 The seat lock is located to the right of the seat. You can lock it with the ignition key. 100108-10 Owner's manual 5.29 You can find the owner's manual in its protective case on the underside of the seat. ...
CONTROLS Tool set 5.30 The tool set is located in the storage compartment under the seat. 500032-10 Passenger footrests 5.31 The passenger footrests can be folded in and out. Possible states Passenger footrests folded up – For operation without a passenger. •...
CONTROLS Shift lever 5.32 The shift lever is mounted on the left side of the engine. 100110-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100111-10...
CONTROLS Foot brake lever 5.33 Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 100183-10 Side stand 5.34 The side stand is coupled with the safety electric starter system - see the riding instruc- ...
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. –...
When using your vehicle, 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.
GENERAL TIPS AND HINTS ON PREPARING FOR USE Loading the vehicle Warning Danger of accidents Unstable riding behavior. – 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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GENERAL TIPS AND HINTS ON PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( p.
RIDING INSTRUCTIONS – Sit on the motorcycle and check the rear mirror setting. Starting Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
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RIDING INSTRUCTIONS – 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 2 seconds.
RIDING INSTRUCTIONS Starting up – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
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RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
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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. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
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.) Warning Danger of accidents Failure of brake system.
RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.
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RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components get very hot when the machine is driven. – Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run.
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
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RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 32) – Fill the fuel tank with fuel up to measurement Guideline Level 50 mm (1.97 in) Total fuel tank 13.5 l Super unleaded (ROZ 95 / RON 95 / capacity, approx.
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A Engine • • • • • Change the engine oil and filter, clean the oil screens. p. 115) • • Check and adjust valve clearance.
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SERVICE SCHEDULE K10N K50A K100A Attachments Check the headlight setting. ( p. 100) • • • • • Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • •...
K50A: every 5,000 km (3,107 mi) K100A: every 10,000 km (6,214 mi) J1A: annually J2A: every 2 years Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service. •...
MAINTENANCE WORK ON FRAME AND ENGINE Jacking up front of motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the rear of the motorcycle. ( p.
MAINTENANCE WORK ON FRAME AND ENGINE Jacking up rear of motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the work stand and screw it into the link forks. Work stand adapter (61029055110) Work stand rear (61029055100) –...
MAINTENANCE WORK ON FRAME AND ENGINE Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .
Adjusting the rebound damping of the shock absorber Danger 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.) – Turn adjusting screw clockwise to the last perceptible click.
MAINTENANCE WORK ON FRAME AND ENGINE Guideline Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase rebound damping; turn counterclockwise to reduce rebound damping. Bleeding the fork legs – Lean the motorcycle on the side stand.
MAINTENANCE WORK ON FRAME AND ENGINE Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 62) 400678-01 Cleaning the chain 9.10 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...
MAINTENANCE WORK ON FRAME AND ENGINE 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.
MAINTENANCE WORK ON FRAME AND ENGINE – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upwards near the vertical rib of the swingarm and measure the chain tension Info The upper chain section must be taut.
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MAINTENANCE WORK ON FRAME AND ENGINE – Check the chain tension. ( p. 63) – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right...
The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. 100132-10 –...
When the chain is replaced, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets. For safety reasons, the chain has no chain joint. Always have the chain 700152-01 changed in an authorized KTM workshop, where the necessary tool is available.
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 in several places to ensure that it conforms to measurement ...
(Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
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MAINTENANCE WORK ON FRAME AND ENGINE 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. Info Never user DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
9.19 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. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable.
(Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
Clean up overflowed or spilt brake fluid immediately with water. 100176-10 Checking the rear brake linings 9.23 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.)
MAINTENANCE WORK ON FRAME AND ENGINE Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable.
MAINTENANCE WORK ON FRAME AND ENGINE – Loosen screws – Unscrew screw about 6 turns, press your hand on the screw to push the wheel spin- dle out of the fork stub. Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs.
MAINTENANCE WORK ON FRAME AND ENGINE – Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point. Fix the hand brake lever while it is activated. The brake calipers straighten. –...
MAINTENANCE WORK ON FRAME AND ENGINE – Remove nut . Remove chain adjuster . Holding the rear wheel, withdraw the wheel spindle – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. 601003-10 –...
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MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. – Check the rear hub rubber dampers. p.
MAINTENANCE WORK ON FRAME AND ENGINE – Operate the foot brake lever repeatedly until the brake linings press up against the brake disc and there is a pressure point. – Taking rear from work stand. ( p. 58) Checking the rear hub rubber dampers 9.28 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers.
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.
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MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be rough- ened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.
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 five years.
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.
MAINTENANCE WORK ON FRAME AND ENGINE Removing the seat 9.32 – Insert the ignition key in the seat lock and turn it 45° counterclockwise. – Lift up the seat at the rear, pull it back and remove from above. 100108-10 Mounting the seat 9.33...
MAINTENANCE WORK ON FRAME AND ENGINE Reinstalling the fuel tank 9.34 – Remove the seat. ( p. 86) – Remove screw Info The fuel lines do not need to be disconnected. 100173-10 – Lay a cloth over the subframe and straighten the steering. ...
MAINTENANCE WORK ON FRAME AND ENGINE Positioning the fuel tank 9.35 – Remove the cloth from between the compensating tank and the spoiler. 100174-11 – Carefully move the fuel tank forwards and lower it. – Mount and tighten the screw with the rubber bushing and bearing sleeve.
MAINTENANCE WORK ON FRAME AND ENGINE Removing the battery 9.36 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
Environmental hazard Battery parts and acid are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
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MAINTENANCE WORK ON FRAME AND ENGINE 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. Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery.
MAINTENANCE WORK ON FRAME AND ENGINE – 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 generator. With this device, you cannot overcharge the battery. Info Never remove lid ...
MAINTENANCE WORK ON FRAME AND ENGINE Info The main fuse protects all power consumers of the vehicle. It is in the housing of the starter relay next to the battery. – Switch off all power consumers and the engine. – Remove the seat.
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MAINTENANCE WORK ON FRAME AND ENGINE – Open fuse box cover 100153-10 – Remove the faulty fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10A - clock, ignition (EFI control unit) Fuse 3 - 10A - throttle valve control unit Fuse 4 - 10A - fuel pump Fuse 5 - 10A - radiator fan...
MAINTENANCE WORK ON FRAME AND ENGINE Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.
MAINTENANCE WORK ON FRAME AND ENGINE – Pull the bulb holder of the parking light out of the headlight housing. – Pull the plug-in connector off the headlight. – Place the headlight mask to one side. 100156-10 Refitting the headlight mask with the headlight 9.42 –...
MAINTENANCE WORK ON FRAME AND ENGINE – Position the headlight mask. Mount and tighten screws Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check lighting function. 100155-11 Changing the headlight bulb 9.43 Note Damage to reflector Reduced luminance. –...
MAINTENANCE WORK ON FRAME AND ENGINE – Take the rubber cap off the headlight bulb. – Turn the bulb holder about 30° counterclockwise and remove it. – Take the headlight bulb out of the headlight housing. – Insert a new headlight bulb into the headlight housing. Headlight (H4 / P43t socket) ( p.
MAINTENANCE WORK ON FRAME AND ENGINE – Pull the parking light bulb out of the holder. – Insert a new parking light bulb in the holder. Parking light (W5W / socket W2,1x9,5d) ( p. 142) – Refit the headlight mask with the headlight. ( p.
MAINTENANCE WORK ON FRAME AND ENGINE – Position the diffuser. – Insert the screw and first turn it counterclockwise until it engages in the thread with a soft jerk. Tighten the screw slightly. – Check that the turn signal system is functioning properly. Checking the headlight setting 9.46 –...
MAINTENANCE WORK ON FRAME AND ENGINE – Use a screwdriver (see illustration) to adjust the headlight range. Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (made in: Checking headlight adjustment). Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.
MAINTENANCE WORK ON FRAME AND ENGINE Cooling takes place by means of the air stream and a radiator fan , which is controlled by a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
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MAINTENANCE WORK ON FRAME AND ENGINE Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the cap of the compensating tank – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) »...
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MAINTENANCE WORK ON FRAME AND ENGINE – Screw off 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.
MAINTENANCE WORK ON FRAME AND ENGINE Checking the coolant level 9.50 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool- ing system to cool down.
MAINTENANCE WORK ON FRAME AND ENGINE – Screw off radiator cap and check the coolant level in the radiator. The radiator must be completely filled. » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p.
MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
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MAINTENANCE WORK ON FRAME AND ENGINE Condition Fuel tank is reset or removed. – Remove radiator cap 100189-10 – 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 the bleeder screw immediately.
MAINTENANCE WORK ON FRAME AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space. –...
MAINTENANCE WORK ON FRAME AND ENGINE – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw – When adjusting the clutch lever make sure that there is a minimum clearance to other parts of the vehicle.
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the basic position of the shift lever 9.55 – Remove screw and remove shift lever 601021-10 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited.
MAINTENANCE WORK ON FRAME AND ENGINE Checking/rectifying the fluid level of the hydraulic clutch 9.56 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...
Adjusting the play in the throttle cable 9.58 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut – Set the play in the throttle cable by turning the adjusting screw ...
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the handlebar angle 9.59 – Loosen screws – Move the handlebar to the desired position and slightly tichten the screws. – Move the handlebar carefully in both directions as far as it will go. »...
MAINTENANCE WORK ON FRAME AND ENGINE Condition The engine is at operating temperature. – 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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MAINTENANCE WORK ON FRAME AND ENGINE 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. Info Drain the engine oil only when the engine is warm. –...
MAINTENANCE WORK ON FRAME AND ENGINE Removing the oil filter 9.63 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws . Remove oil filter with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area.
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MAINTENANCE WORK ON FRAME AND ENGINE 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. – Place a suitable container under the engine. – Remove plug with oil screen and the O-rings.
MAINTENANCE WORK ON FRAME AND ENGINE – Position oil screen with the O-rings. – Mount and tighten plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 700111-01 – Position oil screen with the O-rings. ...
MAINTENANCE WORK ON FRAME AND ENGINE – Remove the oil filler plug with O-ring from the clutch cover and fill up with engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 151) Alternative engine Engine oil (SAE 10W/50) p.
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MAINTENANCE WORK ON FRAME AND ENGINE – Remove the oil filler plug with O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 10W/60) (00062010035) ( p. 151) Engine oil (SAE 10W/50) ( p. 151) Info For optimal performance of the engine oil, do not mix different types of engine oil.
Reconnect coupling of fuel hose connection. connected – Socket connector of wiring harness Clean socket connector and treat it with contact oxidized spray. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault.
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– Fuel filter very dirty Have the fuel filter changed. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
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TROUBLESHOOTING Faults Possible cause Action – Headlight and parking light not func- Fuse 7 blown Change the fuses of individual power consumers. tioning p. 93) – Turn signal, brake light and horn not Fuse 6 blown Change the fuses of individual power consumers. functioning p.
BLINK CODE Blink code FI of warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code FI of warning lamp (MIL) 09 FI warning lamp (MIL) flashes briefly 9x...
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BLINK CODE Blink code FI of warning lamp (MIL) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI of warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short...
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BLINK CODE Blink code FI of warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil cylinder 1 - circuit fault Blink code FI of warning lamp (MIL) 54 FI warning lamp (MIL) flashes 5x long, 4x short Error level condition Secondary air valve - short circuit to ground or open circuit Blink code FI of warning lamp...
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BLINK CODE Blink code FI of warning lamp (MIL) 41 FI warning lamp (MIL) flashes 4x long, 1x short Error level condition Fuel pump relay - short circuit to ground or open circuit Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Hall type sensor EPT throttle motor drive - circuit fault...
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BLINK CODE Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Error level condition Rollover sensor - input signal too low Rollover sensor - input signal too high Blink code FI of warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition...
CLEANING Cleaning motorcycle 12.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
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CLEANING Warning Danger of accidents Reduced braking due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
PROTECTIVE TREATMENT FOR WINTER OPERATION Protective treatment for winter operation 13.1 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt. –...
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the rear of the motorcycle. ( p. 58) –...
STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. Putting into operation after storage 14.2 –...
TECHNICAL DATA - ENGINE Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter, automatic decompressor...
TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel Front 175 mm (6.89 in) rear 175 mm (6.89 in) Brake system Front Disc brake with radially screwed four-piston brake caliper, floating...
TECHNICAL DATA - CHASSIS Steering head angle 63.5° Wheelbase 1,472±15 mm (57.95±0.59 in) Seat height unloaded 840 mm (33.07 in) Ground clearance unloaded 210 mm (8.27 in) Weight without fuel approx. 154 kg (340 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.)
120/70 R 17 M/C 58H TT 160/60 R 17 M/C 69H TT Bridgestone BT090F Bridgestone BT090R Pro Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 17.2 Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.
TECHNICAL DATA - FORK Fork part number 14.18.7E.47 Fork WP Suspension Up Side Down 4860 ROMA Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring length with preload spacer(s) 430 mm (16.93 in) Spring rate Soft 4.8 N/mm (27.4 lb/in)
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.9E.47 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring preload 10 mm (0.39 in) Spring rate Weight of rider: 65…...
– Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
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155) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
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– ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
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.