KTM 990 Supermoto R Owner's Manual
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KTM 990 Supermoto R Owner's Manual

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OWNER'S MANUAL
2010
990 Supermoto R EU
990 Supermoto R FR
990 Supermoto R AUS/UK
990 Supermoto T EU
990 Supermoto T FR
990 Supermoto T AUS/UK
Art. no. 3211519en

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  • Page 1 OWNER'S MANUAL 2010 990 Supermoto R EU 990 Supermoto R FR 990 Supermoto R AUS/UK 990 Supermoto T EU 990 Supermoto T FR 990 Supermoto T AUS/UK Art. no. 3211519en...
  • Page 3 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 enormous pleasure if you service and maintain it accordingly.
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Combination instrument - speedometer....... 27 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........6 Setting kilometers or miles ..........27 IMPORTANT INFORMATION ........... 7 Combination instrument - time .......... 28 VIEW OF VEHICLE..............12 Setting the clock .............. 29 View of vehicle, front left side (vehicle differs slightly from photo) ................
  • Page 6 TABLE OF CONTENTS Starting ................45 Checking the chain, rear sprocket and engine sprocket..75 Starting up ..............46 Checking the front brake discs........... 77 Shifting, riding ..............47 Checking the rear brake disc..........78 Braking ................50 Adjusting the basic position of the hand brake lever..... 79 Stopping, parking .............
  • Page 7 TABLE OF CONTENTS Changing the turn signal bulb .......... 113 IMMOBILIZER BLINK CODE..........154 Changing the brake light bulb .......... 114 ENGINE CONTROL BLINK CODE ......... 156 Changing the tail light bulbs..........118 TROUBLESHOOTING............162 Changing the license plate lamp ........122 CLEANING.................

  • Page 8: 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 serviced opti- mally by specially trained experts using the specialist tools required.

  • Page 9: Important Information

    Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's ser- vice record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 10 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.
  • Page 11 IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Secure the motorcycle against falling over or rolling away using straps or other suitable devices. Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons.
  • Page 12 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 may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (vehicle differs slightly from photo) B00143-10...
  • Page 15 VIEW OF VEHICLE Combination instrument Filler cap Rear mirror Clutch lever Seat Handrails Shock absorber compression damping Shock absorber spring preload Engine number Shift lever Oil level viewer...

  • Page 16: View Of Vehicle, Rear Right Side (Vehicle Differs Slightly From Photo)

    VIEW OF VEHICLE View of vehicle, rear right side (vehicle differs slightly from photo) B00142-10...
  • Page 17 VIEW OF VEHICLE Seat lock Light switch, headlight flasher switch, indicator switch, horn button Emergency OFF switch, electric starter button Hand brake lever Fork spring preload, fork rebound damping Chassis number Fork compression damping Type label Foot brake lever Passenger footrests Shock absorber rebound damping...

  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number/type label Chassis number is embossed in the steering head at the right.  Type label is located on the bottom frame tube on the right.  B00146-10...

  • Page 19: Key Number

    LOCATION OF SERIAL NUMBERS Key number The Code number key number can be found on the KEYCODECARD.  Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.

  • Page 20: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  700546-01 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the ...

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 700548-01 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. ...

  • Page 22: Light Switch

    CONTROLS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – The light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on –...

  • Page 23: 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 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 –...

  • Page 24: Ignition/Steering Lock

    CONTROLS Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp. Info The ignition may only be switched on using a black ignition key. Use the orange programming key to activate and deactivate the black ignition key. Possible states Ignition OFF –...

  • Page 25: Emergency Off Switch

    The second black ignition key is activated when the vehicle is shipped. Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop, but they must be activated before use. Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 26: Combination Instrument

    CONTROLS Combination instrument 5.11 The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. Function buttons  Tachometer  Indicator lights  Display  400920-10 Combination instrument - function buttons 5.12 You can change the display mode with the MODE button ...

  • Page 27: Combination Instrument - Tachometer

    CONTROLS Combination instrument - tachometer 5.13 The tachometer shows the engine speed in revolutions per minute.  The red marking shows the excess speed range of the engine.  400922-10 Combination instrument - indicator lamps 5.14 The indicator lamps offer additional information about the operating state of the motorcy- cle.

  • Page 28: Combination Instrument - Display

    CONTROLS The oil indicator lamp lights up red – The oil pressure is too low. Warning lamp FI (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system.

  • Page 29: Combination Instrument - Speedometer

    CONTROLS LEnGth Following the display function test, the LEnGth wheel circumference is shown for one sec- ond. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series pro- duction tire. The display then changes to the last selected mode. 400837-01 Combination instrument - speedometer 5.16...

  • Page 30: Combination Instrument - Time

    CONTROLS Condition The motorcycle is standing. – Switch on the ignition by turning the ignition key to the ON 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.

  • Page 31: Setting The Clock

    CONTROLS Setting the clock 5.19 Condition The motorcycle is standing. – Switch on the ignition by turning the ignition key to the ON 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.

  • Page 32: Combination Instrument - Setting/Resetting Trip 1

    CONTROLS Combination instrument - setting/resetting TRIP 1 5.21 Info The TRIP 1 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again.

  • Page 33: Combination Instrument - Trip F Display

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 Combination instrument - TRIP F display 5.23...

  • Page 34: Combination Instrument - Ambient Temperature Display

    CONTROLS Combination instrument - ambient temperature display 5.24 The ambient temperature is displayed in °C or °F.  400893-13 Setting the temperature units 5.25 Condition The motorcycle is standing. – Switch on the ignition by turning the ignition key to the ON position.

  • Page 35: Combination Instrument - Warning Of Slippery Roads

    CONTROLS Combination instrument - warning of slippery roads 5.26 The ice symbol lights up to indicate an increased danger of slippery roads. The ice symbol appears in the display when the ambient temperature drops below the specified value. Temperature 3 °C (37 °F) The ice symbol goes out in the display when the ambient temperature rises above the specified value again.

  • Page 36: Opening The Filler Cap

    CONTROLS Opening the filler cap 5.28 – Lift the cover of the filler cap and insert the ignition key.  Note Danger of damage Ignition key breakage. – To take pressure off of the ignition key, push down on the filler cap. Damaged igni- tion keys must be replaced.

  • Page 37: Handrails

    CONTROLS Handrails 5.30 The handrails are used for moving the motorcycle around.  If you carry a passenger, the passenger can hold onto the handrails during the trip. 600923-10 Seat lock 5.31 Seat lock is located at the rear under the tail light. ...

  • Page 38: Tool Set

    CONTROLS Tool set 5.32 The tool set is located in the storage compartment under the seat.  600924-10 Helmet lock 5.33 The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen.

  • Page 39: Passenger Footrests

    CONTROLS Passenger footrests 5.34 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • B00127-01 Shift lever 5.35 Shift lever is mounted on the left side of the engine.

  • Page 40: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gear.  B00121-10 Foot brake lever 5.36 Foot brake lever is located in front of the right footrest.  The rear brake is activated using the foot brake lever.

  • Page 41: Side Stand

    CONTROLS Side stand 5.37 Side stand is coupled with the safety start system; see the riding instructions.  Possible states Side stand folded out – The vehicle can be leaned on the side stand. The safety start • system is active. Side stand folded in –...

  • Page 42: General Tips And Hints On Putting Into Operation

    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. –...

  • Page 43: Running In The Engine

    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.

  • Page 44: Loading The Vehicle

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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.
  • Page 45 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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. –...

  • Page 46: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in 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.

  • Page 47: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous 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.

  • Page 48: Starting Up

    RIDING INSTRUCTIONS – Press the emergency OFF switch into the position – Switch on the ignition by turning the ignition key to the ON position. After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 49: Shifting, Riding

    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. –...
  • Page 50 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. –...
  • Page 51 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.

  • Page 52: Braking

    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.

  • Page 53: Stopping, Parking

    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.
  • Page 54 RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.

  • Page 55: Refueling

    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. –...
  • Page 56 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 34) – Fill the fuel tank with fuel up to the lower edge of the fuel filler.  Total fuel tank 19 l (5 US gal) Super unleaded (ROZ 95 / RON 95 / capacity, approx.

  • Page 57: Service Schedule

    Check that the electrical equipment is functioning properly. • • • • • • • • Read out the trouble code memory using the KTM diagnostics tool. • • • • Change the engine oil and filter, clean the oil screens. p. 145) • •...
  • Page 58 Final inspection: Check the vehicle of roadworthiness and take a test ride. • • • • • • • • Read out the fault memory after a test ride using the KTM diagnostics tool. • • • • Make the service entries in the KTM DEALER.NET and service record.
  • Page 59 SERVICE SCHEDULE K10N: Once after 1,000 km (621.4 mi) K75A: Every 7,500 km (4,660 mi) or annually K150A: Every 15,000 km (9,321 mi) or every 2 years K300A: Every 30,000 km (18,641 mi) or every 4 years...

  • Page 60: Maintenance Work On Frame And Engine

    MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle at the front Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle at the rear. ( p.

  • Page 61: Jacking Up Motorcycle At The Rear

    MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle at the rear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the rear of the work stand. Work stand adapter (61029055120) Work stand rear (61029055100) –...

  • Page 62: Fork/Shock Absorber

    MAINTENANCE WORK ON FRAME AND ENGINE Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to your rid- ing style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .
  • Page 63 MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screws clockwise until they stop.  Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline (Supermoto R) Compression damping...

  • Page 64: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the zero position.

  • Page 65: Adjusting The Spring Preload Of The Fork

    MAINTENANCE WORK ON FRAME AND ENGINE Info Turn clockwise to increase suspension damping; turn counterclockwise to reduce damping. Adjusting the spring preload of the fork Info The spring preload defines the initial situation of the spring process of the fork. The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and thus ensures a compromise between maneuverability and stability.

  • Page 66: Bleeding The Fork Legs

    MAINTENANCE WORK ON FRAME AND ENGINE (Supermoto T) Spring preload - Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload, turn counterclockwise to reduce spring preload. Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work.

  • Page 67: Shock Absorber Compression Damping

    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.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.
  • Page 68 MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click.  Info Do not loosen nut  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type.

  • Page 69: Adjusting The High-Speed Compression 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.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 70: Adjusting The Rebound Damping Of The Shock Absorber

    9.13 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 up to the last perceptible click.

  • Page 71: Adjusting The Spring Preload Of The Shock Absorber

    MAINTENANCE WORK ON FRAME AND ENGINE Guideline (Supermoto R) Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks (Supermoto T) Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase suspension damping;...
  • Page 72 MAINTENANCE WORK ON FRAME AND ENGINE Info The spring preload defines the initial situation of the spring process on the shock absorber. The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and thus ensures a compromise between maneuverability and stability.

  • Page 73: Checking The Chain For Dirt

    MAINTENANCE WORK ON FRAME AND ENGINE (Supermoto T) Spring preload Comfort 11 mm (0.43 in) Standard 11 mm (0.43 in) Sport 11 mm (0.43 in) Full payload 13 mm (0.51 in) – Tighten locking ring  Checking the chain for dirt 9.15 –...

  • Page 74: Checking The Chain Tension

    MAINTENANCE WORK ON FRAME AND ENGINE 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 Environmental hazard Hazardous substances cause environmental damage.

  • Page 75: Adjusting The Chain Tension

    MAINTENANCE WORK ON FRAME AND ENGINE – Lean the motorcycle on the side stand. – Shift the transmission to neutral. – In the area after the chain sliding guard, press the chain upward toward the link fork and measure chain tension ...
  • Page 76 MAINTENANCE WORK ON FRAME AND ENGINE – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws on the left and right.  Guideline Chain tension 7 mm (0.28 in) Turn adjusting screws on the left and right so that the markings on the left and ...

  • Page 77: Checking The Chain, Rear Sprocket And Engine Sprocket

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the chain, rear sprocket and engine sprocket 9.19 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Replace the rear sprocket or engine sprocket. Info The rear sprocket, engine sprocket and chain should always be changed together.
  • Page 78 MAINTENANCE WORK ON FRAME AND ENGINE – Shift into neutral, and pull the lower chain section with the specified weight  Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. ...

  • Page 79: Checking The Front Brake Discs

    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 brake disc in several places to see if it conforms to measure- ment ...

  • Page 80: Checking The Rear Brake Disc

    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 brake disc in several places to see if it conforms to measure- ment ...

  • Page 81: Adjusting The Basic Position Of The Hand Brake Lever

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the basic position of the hand brake lever 9.22 – Pull the brake lever forwards. – Adjust the basic setting of the hand brake lever to your hand size by turning adjusting wheel ...

  • Page 82: Checking The Front Brake Fluid Level

    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.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 83: Adding Front Brake Fluid

    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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 84: Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. Brake linings 9.26 The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the brake linings are entered in the homologation documents. Info Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles.
  • Page 85 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.

  • Page 86: Checking The Rear Brake Fluid Level

    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.) – Stand the vehicle upright.
  • Page 87 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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 88: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. B00133-10 Checking the rear brake linings 9.30 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.)

  • Page 89: Removing The Front Wheel

    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.

  • Page 90: Installing The Front Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE – Loosen screws   – Unscrew screw about six turns and press your hand on the screw to push the wheel  spindle out of the fork stub. Remove screw  Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs.
  • Page 91 MAINTENANCE WORK ON FRAME AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is broken or worn: – Replace the wheel bearing. – Grease and mount the left and right spacers and the shaft seal rings. Long-life grease ( p.

  • Page 92: Removing The Rear Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE Guideline Screw, front brake caliper M10x1.25 45 Nm Loctite ® 243™ (33.2 lbf ft) – Remove the fixation of the hand brake lever. – Take the front from the work stand. ( p. 58) –...

  • Page 93: Installing The Rear Wheel

    MAINTENANCE WORK ON FRAME AND ENGINE – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. – Withdraw the wheel spindle. – Pull the rear wheel backward until the brake caliper support hangs free between the brake disc and the wheel rim.
  • Page 94 MAINTENANCE WORK ON FRAME AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is broken or worn: – Replace the wheel bearing. – Remove bushing and bushing . Clean and grease the roll surfaces of the bushing ...

  • Page 95: Checking Rear Hub Shock Absorbers

    MAINTENANCE WORK ON FRAME AND ENGINE – Engage the counter bearing of the brake caliper support and swingarm. Lay the chain  on the rear sprocket and mount the wheel spindle. – Mount chain adjuster and nut   Info Mount the left and right chain adjusters in the same position.

  • Page 96: Checking The Tire Condition

    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.
  • Page 97 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.

  • Page 98: Checking The Tire Air Pressure

    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 be changed after 5 years at the latest, regard- less of the actual state of wear.

  • Page 99: Removing The Seat

    MAINTENANCE WORK ON FRAME AND ENGINE – Mount the dust cap. Info The rubber seal in the dust cap prevents air leaking out of the tire if the valve is defective. Removing the seat 9.38 – Insert the ignition key in the seat lock and turn it clockwise.

  • Page 100: Mounting The Helmet Lock On The Vehicle

    MAINTENANCE WORK ON FRAME AND ENGINE Mounting the helmet lock on the vehicle 9.40 Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle. – Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before start- ing out.
  • Page 101 MAINTENANCE WORK ON FRAME AND ENGINE 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. – Never operate the vehicle with a discharged battery or without a battery. –...

  • Page 102: Installing The Battery

    MAINTENANCE WORK ON FRAME AND ENGINE Installing the battery 9.42 – Position the battery in the battery rack. Info The terminals of the battery must face in the direction of travel. – Attach rubber band  – Reconnect the positive (plus) cable of the battery.

  • Page 103: Recharging The Battery

    – 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. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 104 MAINTENANCE WORK ON FRAME AND ENGINE 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. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 105: Changing The Main Fuse

    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 the rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove lid ...
  • Page 106 MAINTENANCE WORK ON FRAME AND ENGINE Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. – Switch off all power consumers and the engine. – Remove the seat. ( p. 97) –...

  • Page 107: Changing The Fuses Of Individual Power Consumers

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the fuses of individual power consumers 9.45 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. Info The fuse box containing the fuses of individual power consumers is located under the seat.
  • Page 108 MAINTENANCE WORK ON FRAME AND ENGINE Guideline Fuse IGNITION, FUEL PUMP - 10A - ignition, fuel pump, immobilizer, alarm system (optional) Fuse H/L BEAM, POSITION - 15A - high beam, low beam, parking light, license plate lamp Fuse HORN, BRAKE LIGHT - 10A - horn, brake light, hazard warning flasher Fuse FAN - 10A - radiator fan Fuse POWER RELAY - 10A - ignition (EFI control unit) Fuse ACC1, CLOCK - 10A - combination instrument, socket, supplementary devices...

  • Page 109: Changing The Headlight Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the headlight bulb 9.46 Note Damage to reflector Reduced luminance. – 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.
  • Page 110 MAINTENANCE WORK ON FRAME AND ENGINE (Supermoto T) – Remove the cover. Info For purposes of illustration only, the following steps are shown with the headlight mask removed for this model. Removal is not necessary. 700604-01 – Disconnect plug-in connector ...
  • Page 111 MAINTENANCE WORK ON FRAME AND ENGINE – Position the retaining clamp. – Mount rubber cap  – Position plug-in connection  700592-11 (Supermoto R) – Position holes onto holding lugs   700591-11...

  • Page 112: Changing The Parking Light Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the headlight mask. Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) B00137-11 (Supermoto T) – Mount the cover. – Check that the lighting is functioning properly. 700604-01 Changing the parking light bulb 9.47...
  • Page 113 MAINTENANCE WORK ON FRAME AND ENGINE (Supermoto R) – Remove screws  B00137-10 – Cover the fender with a cloth. – Swing the headlight mask forward and pull it upward out of holding lugs  700591-10 (Supermoto T) – Remove the cover. Info For purposes of illustration only, the following steps are shown with the headlight mask removed for this model.
  • Page 114 MAINTENANCE WORK ON FRAME AND ENGINE – Pull the parking light carefully out of the holder.  – Remove the bulb. – Position a new light bulb in the holder. Parking light (W5W/socket W2.1x9.5d) ( p. 177) – Carefully position the holder with the bulb into the holder in the headlight. 700594-01 (Supermoto R) –...

  • Page 115: Changing The Turn Signal Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the headlight mask. Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) B00137-12 (Supermoto T) – Mount the cover. – Check that the lighting is functioning properly. 700604-01 Changing the turn signal bulb 9.48...

  • Page 116: Changing The Brake Light Bulb

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove the screw on the rear of the turn signal housing. – Carefully remove diffuser  – Press bulb carefully into the socket, turn it counterclockwise by about 30°, and pull  it out of the socket. –...
  • Page 117 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Remove screws on the left and right rear side part.  – Remove the rear side part. B00138-10 – Remove screws  – Remove the top part. 700599-10...
  • Page 118 MAINTENANCE WORK ON FRAME AND ENGINE – Turn bulb socket counterclockwise all the way and take it out of the tail light.  – Push the bulb carefully into the socket, turn it counterclockwise and pull it out of the socket.
  • Page 119 MAINTENANCE WORK ON FRAME AND ENGINE – Position the rear side parts. – Mount and tighten screws  Guideline Remaining chassis screws 5 Nm (3.7 lbf ft) – Mount and tighten screws on the left and right rear side part. ...

  • Page 120: Changing The Tail Light Bulbs

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the tail light bulbs 9.50 Note Damage to reflector Reduced luminance. – 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.
  • Page 121 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Remove screws on the left and right rear side part.  – Remove the rear side part. B00138-10 – Remove screws  – Remove the top part. 700599-10...
  • Page 122 MAINTENANCE WORK ON FRAME AND ENGINE – Pull bulb holders carefully out of the bracket.  – Remove the bulb. – Position a new light bulb in the holder. Tail light (WR5W/socket W2.1x9.5d) ( p. 178) – Carefully position the holders with the bulbs into the holder in the tail light. 700601-10 –...
  • Page 123 MAINTENANCE WORK ON FRAME AND ENGINE – Position the rear side parts. – Mount and tighten screws  Guideline Remaining chassis screws 5 Nm (3.7 lbf ft) – Mount and tighten screws on the left and right rear side part. ...

  • Page 124: Changing The License Plate Lamp

    MAINTENANCE WORK ON FRAME AND ENGINE Changing the license plate lamp 9.51 – Remove screws  – Remove the license plate lamp cover. 700602-01 – Pull holder carefully out of the bracket.  – Remove the bulb. – Position a new light bulb in the holder. License plate lamp (W5W/socket W2.1x9.5d) ( p.

  • Page 125: Checking The Headlight Setting

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the cover. – Mount and tighten screws  – Check that the license plate lamp is functioning properly. 700602-10 Checking the headlight setting 9.52 – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark 0 0 A at the level of the center of the headlight.

  • Page 126: Adjusting Headlight Range

    MAINTENANCE WORK ON FRAME AND ENGINE » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 124) Adjusting headlight range 9.53 – Check the headlight setting. ( p. 123) (Supermoto R) –...

  • Page 127: Activating/Deactivating The Ignition Key

    MAINTENANCE WORK ON FRAME AND ENGINE Activating/deactivating the ignition key 9.54 Info The orange programming key must only be used for activating and deactivating! If a black ignition key is lost or replaced, the black ignition keys must be activated/deactivated using the orange programming key. This will also prevent the vehicle from being operated without authorization with the lost black ignition key.
  • Page 128 MAINTENANCE WORK ON FRAME AND ENGINE – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position FI Warning lamp (MIL) lights up, switches off, and then starts to flash. Immobilizer indicator lamp lights up, switches off briefly and flashes;...
  • Page 129 MAINTENANCE WORK ON FRAME AND ENGINE All black ignition keys are deactivated. – Order a new black ignition key according to the key number on the KEYCODECARD and activate it. Activating the ignition key: – Press the emergency OFF switch into the position –...

  • Page 130: Cooling System

    MAINTENANCE WORK ON FRAME AND ENGINE – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the programming key. All black ignition keys are activated included in this job sequence are activated. Cooling system 9.55 The water pump...

  • Page 131: Checking The Antifreeze And Coolant Level

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the antifreeze and coolant level 9.56 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
  • Page 132 MAINTENANCE WORK ON FRAME AND ENGINE – Add coolant to the upper marking. Alternative 1 Coolant ( p. 187) Alternative 2 Coolant (mixed ready to use) ( p. 187) » If there is no coolant in the compensating tank: – Check the cooling system for leaks.

  • Page 133: Checking The Coolant Level In The Compensating Tank

    MAINTENANCE WORK ON FRAME AND ENGINE Checking the coolant level in the compensating tank 9.57 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 134: Draining The Coolant

    MAINTENANCE WORK ON FRAME AND ENGINE – Mount the cap of the compensating tank. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! – Fill/bleed the cooling system. p.

  • Page 135: Filling/Bleeding The Cooling System

    MAINTENANCE WORK ON FRAME AND ENGINE – Place a suitable container under the radiator. – Remove radiator cap  – Remove screw  – Completely drain the coolant. – Mount screw with a new seal ring and tighten it.  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft)
  • Page 136 MAINTENANCE WORK ON FRAME AND ENGINE – Reset the fuel tank. ( p. 136) – Ensure that the drain plug on the radiator and the water pump cover are tightened. – Remove bleeder screw  700629-10 – Position the vehicle as shown and secure it against rolling. Height difference must ...
  • Page 137 MAINTENANCE WORK ON FRAME AND ENGINE – Remove the radiator cap and pour in coolant until it emerges without bubbles at the vent hole, and then immediately mount and tighten the bleeder screw  Alternative 1 Coolant ( p. 187) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 138: Reinstalling The Fuel Tank

    MAINTENANCE WORK ON FRAME AND ENGINE Reinstalling the fuel tank 9.60 – Remove the seat. ( p. 97) (Supermoto T) – Remove the mask spoiler. ( p. 139) – Remove screws and the spoiler on both sides.  B00141-10 – Remove screw on both sides.

  • Page 139: Positioning The Fuel Tank

    MAINTENANCE WORK ON FRAME AND ENGINE (Supermoto R) – Remove screw  – Carefully push the fuel tank back. 700652-11 Positioning the fuel tank 9.61 – Carefully push the fuel tank forward. (Supermoto T) The fuel tank fixations must engage in the recesses. (Supermoto R) –...
  • Page 140 MAINTENANCE WORK ON FRAME AND ENGINE – Install and tighten screw with the bearing sleeve and rubber sleeve on both sides.  Check the fuel tank for tightness. Guideline Remaining chassis screws 25 Nm (18.4 lbf ft) – Check the routing of the fuel lines. B00147-10 –...

  • Page 141: Removing The Mask Spoiler (Supermoto T)

    MAINTENANCE WORK ON FRAME AND ENGINE Removing the mask spoiler (Supermoto T) 9.62 – Remove screws  700632-01 – Remove screws  – Remove the mask spoiler. 700634-01...

  • Page 142: Installing The Mask Spoiler (Supermoto T)

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Remove the inside trim of the mask spoiler. – Repeat the operation on the opposite side. 700633-01 Installing the mask spoiler (Supermoto T) 9.63 – Position the inside trim of the mask spoiler. –...

  • Page 143: Adjusting The Basic Position Of The Clutch Lever

    MAINTENANCE WORK ON FRAME AND ENGINE – Position the mask spoiler. – Mount and tighten screws  700632-10 – Mount and tighten screws  – Repeat the operation on the opposite side. 700634-10 Adjusting the basic position of the clutch lever 9.64 Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 144: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

    MAINTENANCE WORK ON FRAME AND ENGINE (Supermoto R) – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  700548-10 (Supermoto T) – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw ...

  • Page 145: Checking The Play In The Throttle Cable

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Remove cover with membrane   – Check the fluid level. Fluid level below top edge of container 4 mm (0.16 in) » If the coolant level does not meet specifications: –...

  • Page 146: Adjusting The Play In The Throttle Cable

    Adjusting the play in the throttle cable 9.67 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the basic position. – Loosen counter nut  – Set the play in the throttle cable by turning adjusting screw ...

  • Page 147: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    MAINTENANCE WORK ON FRAME AND ENGINE – Switch off the engine. – Park the motorcycle on a horizontal surface in a vertical position (not on the side stand). – Read the engine oil level at oil level viewer  The engine oil level must be between the upper and lower marking.
  • Page 148 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. –...
  • Page 149 MAINTENANCE WORK ON FRAME AND ENGINE – Pull oil screen out of the engine case with pliers.  700612-10 – Place a suitable container under the engine. – Remove oil drain plug  – Fully drain the engine oil out of the oil tank. –...
  • Page 150 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screw connections and move the oil line to one side.  – Remove screws. Take off oil filter cover with the O-ring.  – Pull oil filter out of the oil filter housing. ...
  • Page 151 MAINTENANCE WORK ON FRAME AND ENGINE – Check seal ring of the oil sieve for damage and correct seating.  – Insert oil sieve into the oil tank.  700614-10 – Position oil line . Mount and tighten screws  ...

  • Page 152: Filling Up With Engine Oil

    MAINTENANCE WORK ON FRAME AND ENGINE – into the engine case with the TOP marking facing up. Slide oil sieve  – Check the form ring in cover for damage and correct seating.  – Position the cover. Mount and tighten the screws. Guideline Screw, clutch cover 10 Nm (7.4 lbf ft)

  • Page 153: Adding Engine Oil

    MAINTENANCE WORK ON FRAME AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous 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.

  • Page 154: Ignition Curve Plug-In Connector

    MAINTENANCE WORK ON FRAME AND ENGINE – Remove plug and add engine oil to the top marking   Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 188) Condition External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p.

  • Page 155: Adjusting The Ignition Curve To The Fuel Quality

    MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the ignition curve to the fuel quality 9.74 – Switch off the ignition by turning the ignition key to the OFF position. – Remove the seat. ( p. 97) To activate the ignition curve for low octane fuel: Note Engine damage Low-quality fuel damages the engine.

  • Page 156: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Blink code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition Malfunction, antenna of immobilizer control unit Blink code of immobilizer indica-...
  • Page 157 IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition Immobilizer control unit not activated Blink code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica-...

  • Page 158: Engine Control Blink Code

    ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 02 Warning lamp FI (MIL) flashes 2x short Error level condition Circuit ignition pulse generator - circuit fault Blink code FI of warning lamp (MIL) 06 Warning lamp FI (MIL) flashes 6x short Error level condition Throttle valve sensor circuit A - input signal too low Throttle valve sensor circuit A - input signal too high...
  • Page 159 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 12 Warning lamp FI (MIL) flashes 1x long, 2x short Error level condition Coolant temperature sensor - input signal too low Coolant temperature sensor - input signal too high Blink code FI of warning lamp (MIL) 13 Warning lamp FI (MIL) flashes 1x long, 3x short...
  • Page 160 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 18 Warning lamp FI (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Blink code FI of warning lamp (MIL) 24 Warning lamp FI (MIL) flashes 2x long, 4x short Error level condition Power supply - circuit fault...
  • Page 161 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 37 Warning lamp FI (MIL) flashes 3x long, 7x short Error level condition Ignition coil cylinder 1 - circuit fault Blink code FI of warning lamp (MIL) 38 Warning lamp FI (MIL) flashes 3x long, 8x short Error level condition Ignition coil cylinder 2 - circuit fault Blink code FI of warning...
  • Page 162 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 49 Warning lamp FI (MIL) flashes 4x long, 9x short Error level condition Motor drive circuit A - circuit fault Blink code FI of warning lamp (MIL) 50 Warning lamp FI (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Blink code FI of warning...
  • Page 163 ENGINE CONTROL BLINK CODE Blink code FI of warning lamp (MIL) 81 Warning lamp FI (MIL) flashes 8x long, 1x short Error level condition Immobilizer control unit - circuit fault Blink code FI of warning lamp (MIL) 91 Warning lamp FI (MIL) flashes 9x long, 1x short Error level condition Malfunction in CAN bus communication...

  • Page 164: Troubleshooting

    Reconnect coupling of fuel hose connection. connected – Socket connector of cable harness oxi- Clean the socket connector and treat it with con- dized tact spray. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 165 Air filter very dirty Change the air filter. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Ignition curve for low octane fuel acti- Refuel with fuel with an octane rating of 95 or vated higher.
  • Page 166 TROUBLESHOOTING Faults Possible cause Action – Headlight and parking light not func- Fuse H/L BEAM, POSITION blown Change the fuses of individual power consumers. tioning p. 105) – Turn signal, hazard warning flasher, Fuse HORN, BRAKE LIGHT, SPEEDO Change the fuses of individual power consumers. brake light and horn are not functional blown p.

  • Page 167: Cleaning

    CLEANING Cleaning motorcycle 13.1 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.
  • Page 168 CLEANING Warning Danger of accidents Reduced braking efficiency 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, applying the brakes occasionally. Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate.

  • Page 169: Protective Treatment For Winter Operation

    PROTECTIVE TREATMENT FOR WINTER OPERATION Conserving for winter operation 14.1 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. –...

  • Page 170: Storage

    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 motorcycle at the rear. ( p. 59) –...

  • Page 171: Putting Into Operation After Storage

    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 15.2 –...

  • Page 172: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 999 cm³ (60.96 cu in) Stroke 62.4 mm (2.457 in) Bore 101 mm (3.98 in) Compression ratio 11.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter Exhaust 33 mm (1.3 in) Intake...

  • Page 173: Capacity- Engine Oil

    TECHNICAL DATA - ENGINE 5th gear 24:27 6th gear 27:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 450 W Spark plug NGK DCPR8E Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump Cold start device...

  • Page 174: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet 6 Nm (4.4 lbf ft) Loctite 243™ – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 175 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, valve cover 10 Nm (7.4 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) ® Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite 243™ ® Stud, cylinder head in cylinder Loctite 243™...
  • Page 176 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Nut, cylinder head on chain shaft Step 1 Lubricated with engine oil 25 Nm (18.4 lbf ft) Step 2 38 Nm (28 lbf ft) – Plug, clutch lubrication 15 Nm (11.1 lbf ft) – Stud, cylinder head in engine case 20 Nm (14.8 lbf ft) –...
  • Page 177 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Nut, primary gear M33LHx1.5 130 Nm (95.9 lbf ft) Loctite 243™...

  • Page 178: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA PA Shock absorber WP Suspension 4618 BAVP DCC Suspension travel Front 160 mm (6.3 in) Rear 180 mm (7.09 in) Brake system Front Double disc brake with radially screwed four-piston brake calipers,...

  • Page 179: Lighting Equipment

    TECHNICAL DATA - CHASSIS Secondary drive ratio 17:41 Chain 5/8 x 5/16” X‑ring Steering head angle 65.6° Wheelbase 1,505 mm (59.25 ±15 ±0.59 Seat height, unloaded (Supermoto R) 875 mm (34.45 in) Seat height, unloaded (Supermoto T) 855 mm (33.66 in) Ground clearance, unloaded 195 mm (7.68 in) Weight without fuel, approx.

  • Page 180: Tires

    120/70 ZR 17 M/C 58W TL 180/55 ZR 17 M/C 73W TL Continental ContiSportAttack Continental ContiSportAttack Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 18.3 Total fuel tank capacity, approx. 19 l (5 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 181: Technical Data - Fork

    TECHNICAL DATA - FORK Supermoto R 19.1 Fork part number 14.18.7E.21 WP Suspension Up Side Down 4860 ROMA PA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport...

  • Page 182: Supermoto T

    TECHNICAL DATA - FORK Supermoto T 19.2 Fork part number 14.18.7E.43 WP Suspension Up Side Down 4860 ROMA PA Fork Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport...

  • Page 183: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Supermoto R 20.1 Shock absorber part number 15.18.7E.03 WP Suspension 4618 BAVP DCC Shock absorber Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns...

  • Page 184: Supermoto T

    TECHNICAL DATA - SHOCK ABSORBER Medium (standard) 140 N/mm (799 lb/in) Spring length 200 mm (7.87 in) Gas pressure 10 bar (145 psi) Static sag 20 mm (0.79 in) Fitted length 372 mm (14.65 in) Shock absorber fluid Shock absorber oil (SAE 2,5) (50180342S1) ( p.
  • Page 185 TECHNICAL DATA - SHOCK ABSORBER Full payload 10 clicks Spring preload Comfort 11 mm (0.43 in) Standard 11 mm (0.43 in) Sport 11 mm (0.43 in) Full payload 13 mm (0.51 in) Spring rate Medium (standard) 140 N/mm (799 lb/in) Spring length 200 mm (7.87 in) Gas pressure...

  • Page 186: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, rear side part (Supermoto T) EJOT Initial screw connection 3.3 Nm (2.43 lbf ft) Subsequent screw connec- tion 2 Nm (1.5 lbf ft) ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 187 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining chassis nuts 30 Nm (22.1 lbf ft) – Remaining chassis screws 25 Nm (18.4 lbf ft) ® Screw, bag carrier (Supermoto T) 15 Nm (11.1 lbf ft) Loctite 243™ – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) –...
  • Page 188 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, upper subframe M10x1.25 45 Nm (33.2 lbf ft) Loctite 243™ – Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft) ® Screw connection, suction line M14x1.5 45 Nm (33.2 lbf ft) Loctite Screw, bottom shock absorber M14x1.5...

  • Page 189: Substances

    – 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 ®...
  • Page 190 SAE ( p. 193) (SAE 10W/50) 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. Fully synthetic engine oil Supplier ® Motorex –...
  • Page 191 – 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...
  • Page 192 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 193: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Strong Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 194 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Fett 2000 Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Universal oil spray Guideline – ® KTM recommends Motorex products.

  • Page 195: 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 specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 196: Index

    INDEX Brake linings ........INDEX front brake, checking ......82 Accessories .
  • Page 197 INDEX kilometers or miles, setting ..... . 27 Engine oil ODO display ....... . . 29 adding .
  • Page 198 INDEX Fuel tank Immobilizer ........22 positioning .
  • Page 199 INDEX removing ........90 Oil screen cleaning .
  • Page 200 INDEX Tachometer ........25 View of vehicle Tail lamp bulbs front left side .
  • Page 201 *3211519en* 3211519en 10/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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