KTM 1190 ADVENTURE R Owner's Manual
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KTM 1190 ADVENTURE R Owner's Manual

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OWNER'S MANUAL
2016
1190 Adventure R
Art. no. 3213390en

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Summary of Contents for KTM 1190 ADVENTURE R

  • Page 1 OWNER'S MANUAL 2016 1190 Adventure R Art. no. 3213390en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, 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 SERIAL NUMBERS ............28 TABLE OF CONTENTS MEANS OF REPRESENTATION ........8 Chassis number ..........28 Symbols used ............8 Type label ............28 Formats used............9 Key number............29 SAFETY ADVICE............10 Engine number ..........30 Use definition - intended use ......
  • Page 6 TABLE OF CONTENTS 6.14 Opening the storage compartment ....... 44 7.9.10 "MTC/ABS" ............ 60 6.15 Closing the storage compartment......44 7.9.11 "Drive Mod" ........... 61 6.16 Seat lock............45 7.9.12 menu overview..........62 6.17 Grab handles ............. 45 7.9.13 "Language" ............ 63 6.18 Luggage rack plate ..........
  • Page 7 TABLE OF CONTENTS 10 RIDING INSTRUCTIONS..........83 13.2 Removing the vehicle from the center stand ..107 10.1 Checks and maintenance measures when 13.3 Removing the seat ........... 108 preparing for use..........83 13.4 Mounting the seat ..........109 10.2 Starting.............
  • Page 8 TABLE OF CONTENTS 14.3 Checking the brake fluid level of the front 16.12 Checking the headlight setting ......177 brake .............. 138 16.13 Adjusting the headlight range......178 14.4 Adding front brake fluid ........ 139 16.14 Activating/deactivating the ignition key ....179 14.5 Checking the front brake linings ......
  • Page 9 TABLE OF CONTENTS 23.3.3 Fuel ............210 23.4 Chassis ............210 23.5 Electrical system..........211 23.6 Tires ............... 212 23.7 Fork..............212 23.8 Shock absorber ..........214 23.9 Chassis tightening torques ........ 215 24 SUBSTANCES ............219 25 AUXILIARY SUBSTANCES ........... 222 26 STANDARDS ..............

  • Page 10: 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 optimally cared for by specially trained experts using the specialist tools required.

  • Page 11: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 12: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses. Info The motorcycle is only authorized for operation on public roads in the homologated version.

  • Page 13: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: Overview Of Labels

    SAFETY ADVICE Overview of labels S00934-10...
  • Page 15 SAFETY ADVICE Information on suspension tuning Canada type label Information on emission control Information on chain tension Information on noise emission Information on starting up Information on tires USA type label Technical Information Information on suspension tuning S00936-01...
  • Page 16 SAFETY ADVICE S00935-10 Canada type label Information on emission control S00937-01...
  • Page 17 SAFETY ADVICE Information on chain tension S00938-01 S00939-01 Information on noise emission...
  • Page 18 SAFETY ADVICE Information on starting up S00940-01 Information on tires M00608-01...

  • Page 19: Reporting Safety Defects

    If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives multiple similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 20: Noise Emission Warranty

    Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

  • Page 21: Tampering Warning

    SAFETY ADVICE Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur- chaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 22: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.12 Work rules Special tools are necessary for some of the work.

  • Page 23: Environment

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 24: Important Notes

    Warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 25: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 26: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) S00943-10...
  • Page 27 VIEW OF VEHICLE Socket for electrical accessories ( p. 40) Clutch lever ( p. 32) Seat lock ( p. 45) Grab handles ( p. 45) Luggage rack plate ( p. 46) Passenger footrest ( p. 46) Center stand ( p. 49) Rider footrests ( p.

  • Page 28: 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) S00944-10...
  • Page 29 VIEW OF VEHICLE Combination switch ( p. 33) Filler cap Fork compression adjustment Fork rebound adjustment Emergency OFF switch ( p. 37) Electric starter button ( p. 37) Throttle grip ( p. 33) Hand brake lever ( p. 32) Storage compartment Cooling system compensating tank Foot brake lever ( p.

  • Page 30: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the bottom right of the frame behind the steering head. The chassis number is also shown on the type label. 402294-10 Type label  Type label USA is affixed to the frame behind the steering head at the top right. 0 0 1 402174-10...

  • Page 31: Key Number

    SERIAL NUMBERS Type label Canada  is affixed to the frame behind the steering head at the top left. 402293-11 Key number The key number Code 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.

  • Page 32: Engine Number

    SERIAL NUMBERS Engine number  The engine number is stamped on the right side of the engine. 402296-10 Fork part number  The fork part number is stamped on the inner side of the fork stub. 402295-10...

  • Page 33: Shock Absorber Article Number

    SERIAL NUMBERS Shock absorber article number  The shock absorber article number is stamped on the top of the shock absorber. 402339-10...

  • Page 34: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M00546-10 Hand brake lever  The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate both the front brake and rear brake at the same time.

  • Page 35: Throttle Grip

    CONTROLS Throttle grip  The throttle grip is fitted on the right side of the handlebar. S00216-10 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar. Overview of the left combination switch Light switch ( p.

  • Page 36: Light Switch

    CONTROLS 6.4.2 Light switch  The light switch is fitted on the combination switch on the left. Possible states Low beam on – Light switch in position  . In this position, the low beam and tail light are switched on. High beam on –...

  • Page 37: Menu Switch

    CONTROLS 6.4.4 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the matrix display on the combination instrument.  Button is the UP button.  Button is the DOWN button. ...

  • Page 38: Horn Button

    CONTROLS Info An automatic turn signal switch-off function (ATIR) is available as an optional soft- ware feature. The ATIR function uses a time and distance counter. If the turn signal has been on for at least 10 seconds and 150 meters of riding distance, the turn signal is switched off.

  • Page 39: Switches On The Right Side Of The Handlebar

    CONTROLS Switches on the right side of the handlebar 6.5.1 Emergency OFF switch  The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started.

  • Page 40: Ignition/Steering Lock

    CONTROLS Ignition/steering lock  The ignition/steering lock is located in front of the upper triple clamp. Info The ignition may only be switched on using a black ignition key. With the orange programming key, you can activate or deactivate the black ignition key.

  • Page 41: Locking The Steering

    The black ignition keys are activated when delivered. Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop; they need to be activated for use. Locking the steering Note Danger of damage The parked vehicle may roll away or fall over.

  • Page 42: Unlocking The Steering

    CONTROLS Unlocking the steering – Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove the key. You can now steer the bike again. 400731-01 6.10 Socket for electrical accessories  Socket for electrical accessories is fitted to the left of the combination instrument. It is connected to permanent positive and fuse-protected.

  • Page 43: Opening The Filler Cap

    CONTROLS 6.11 Opening the filler cap 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 44: Closing The Filler Cap

    CONTROLS 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. –  Turn ignition key clockwise. – Fold open filler cap ...

  • Page 45: Fuel Cocks

    CONTROLS – Push down the filler cap and turn the ignition key  counterclockwise until the tank lock closes. Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel.

  • Page 46: Opening The Storage Compartment

    CONTROLS 6.14 Opening the storage compartment –  Press lock in the direction of the arrow and lift the cover at the same time. S00946-10 6.15 Closing the storage compartment –  Press cover downward. The lock engages audibly. S00946-11...

  • Page 47: Seat Lock

    CONTROLS 6.16 Seat lock  The seat lock is located on the left side of the vehicle. It can be unlocked using the ignition key. S00947-10 6.17 Grab handles  The passenger can hold onto grab handles during the trip. M00619-10...

  • Page 48: Luggage Rack Plate

    CONTROLS 6.18 Luggage rack plate  The luggage rack plate is located behind the seat. The base plate of a luggage system (optional) can be attached to the luggage rack plate. The luggage rack plate may not be loaded with more than the specified weight. Maximum permissible load 8 kg (18 lb.) on luggage rack plate...

  • Page 49: Shift Lever

    CONTROLS 6.20 Shift lever  The shift lever is fitted on the left side of the engine. 402299-10 The gear positions can be seen in the figure. The idle position is between the first and second gears. 402299-11...

  • Page 50: Foot Brake Lever

    CONTROLS 6.21 Foot brake lever  Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. 402301-10 6.22 Side stand  The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle.

  • Page 51: Center Stand

    CONTROLS 6.23 Center stand  In addition to the side stand, the vehicle is equipped with a center stand 402031-10...

  • Page 52: Combination Instrument

    COMBINATION INSTRUMENT Overview Matrix display ( p. 51) Tachometer Shift warning light ( p. 54) Segment display Indicator lamps ( p. 52) 402341-10 Activation and test Activation The combination instrument is activated when the ignition is switched on. Info The brightness of the displays is controlled by a brightness sensor in the combina- tion instrument.

  • Page 53: Matrix Display

    COMBINATION INSTRUMENT Matrix display The matrix display is controlled using the menu switch ( p. 35). After the ignition is switched on, the display shows when the next service ( p. 55) is due. If the General warning lamp lights up among the indicator lamps ( p.

  • Page 54: Indicator Lamps

    COMBINATION INSTRUMENT Indicator lamps Possible states The high beam indicator lamp lights up blue – The high beam is switched The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low.

  • Page 55: Message On The Matrix Display

    KTM workshop. General message – General message on operating safety. Visit an autho- rized KTM workshop. ABS warning – ABS is not available. Visit an authorized KTM workshop. Motorcycle traction control – The motorcycle traction control is not avail- 401850-01 able.

  • Page 56: Shift Warning Light

    Battery voltage – The battery voltage is too low. Recharge the battery with a suitable battery charger. Service – A service is due. Contact an authorized KTM workshop. Emergency OFF switch – The emergency OFF switch is off. The messages are displayed in the "Warning" menu.

  • Page 57: Service Display

    COMBINATION INSTRUMENT The shift warning light always 6,500 rpm lights up at service display After the ignition is switched on, the service display appears briefly. The service intervals depend on the distance traveled or the elapsed time. The event that occurs first is given priority.

  • Page 58: Trip 1

    COMBINATION INSTRUMENT 7.9.2 "Trip 1" – Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display. "Trip 1" shows the distance since the last reset, such as between two refueling stops. "Trip 1" runs continuously and counts the distance up to 9999. "Ø...

  • Page 59: General Info

    COMBINATION INSTRUMENT 7.9.4 "General Info" – Press the UP oder DOWN button until the "General Info" menu appears on the matrix dis- play. "Air Temp" indicates the ambient air temperature. "Date" indicates the date. "ODO" indicates the total distance covered. "Battery"...

  • Page 60: Set Favorites

    COMBINATION INSTRUMENT Guideline Tire air pressure, solo/with passenger/full payload Front: with cold tires 2.4 bar (35 psi) Rear: with cold tires 2.9 bar (42 psi) The "TPMS" menu displays the tire pressure of the front and rear tires. "FW" indicates the tire air pressure at the front. "RW"...

  • Page 61: Settings

    COMBINATION INSTRUMENT 7.9.7 "Settings" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. Settings for units or various values are made in the "Settings" menu. Several functions can be enabled or disabled.

  • Page 62: Heating" (Optional)

    COMBINATION INSTRUMENT 7.9.9 "Heating" (optional) – Press UP or DOWN button until the "Heating" menu appears on the matrix display. Press- ing the SET button opens the menu. – Use the SET button to select a heating level or to switch off the heated grips. 402434-02 7.9.10 "MTC/ABS"...

  • Page 63: Drive Mod

    COMBINATION INSTRUMENT 7.9.11 "Drive Mod" – Press the UP or DOWN button until the "Drive Mod" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the UP or DOWN button to navigate through the menu. The SET button can be used to select engine and traction control settings that are coordinated with each other.

  • Page 64: Menu Overview

    COMBINATION INSTRUMENT 7.9.12 menu overview L02901-01...

  • Page 65: Language

    COMBINATION INSTRUMENT "KTM" start screen Menu buttons "Favorites" "Trip 1" "Trip 2" "General Info" "TPMS" (optional) "Set Favorites" "Settings" "Warning" (only active if there are messages) "Heating" (optional) "MTC/ABS" "Drive Mod" 7.9.13 "Language" Condition • The vehicle is stationary. –...

  • Page 66: Distance

    COMBINATION INSTRUMENT 7.9.14 "Distance" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Distance" is highlighted in black on the matrix dis- play.

  • Page 67: Pressure

    COMBINATION INSTRUMENT 7.9.16 "Pressure" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Pressure" is highlighted in black on the matrix dis- play.

  • Page 68: Clock/Date

    COMBINATION INSTRUMENT 7.9.18 "Clock/Date" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Clock/Date" is highlighted in black on the matrix dis- play.

  • Page 69: Heat Grip

    COMBINATION INSTRUMENT 7.9.20 "Heat Grip" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Heat Grip" is highlighted in black on the matrix dis- play.

  • Page 70: Ergonomics

    ERGONOMICS Handlebar position  The holes on the handlebar support are placed at a distance of from the center. 3.5 mm (0.138 in)  Hole distance The handlebar can be mounted in two different positions. In this way, the handlebar can be mounted in the position that is most comfortable for the rider.
  • Page 71 ERGONOMICS Guideline Screw, handlebar support 40 Nm Loctite ® 243™ (29.5 lbf ft) Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure the cables and wiring are positioned correctly. –  Position the handlebar clamps. Mount and evenly tighten screws Guideline Screw, handlebar clamp 20 Nm...

  • Page 72: Adjusting The Wind Shield

    ERGONOMICS Adjusting the wind shield –  Pull the clamping lever in the direction of the arrow. The windshield is unlocked. S00342-10 – Move the wind shield in the required position. S00247-10...

  • Page 73: Adjusting Basic Position Of Clutch Lever

    ERGONOMICS – Push the clamping lever  in the direction of the arrow. The windshield is locked. S00342-11 Adjusting basic position of clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting ...

  • Page 74: Adjusting The Basic Position Of The Hand Brake Lever

    ERGONOMICS Adjusting the basic position of the hand brake lever – Adjust the basic position of the hand brake lever to your hand size by turning adjusting  wheel Info Push the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding.

  • Page 75: Adjusting The Footrests

    ERGONOMICS Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides. –  Remove screw The foot brake lever swings up to the stop. M00622-10 – Remove cotter pin  with washer ...
  • Page 76 ERGONOMICS – Remove screws  M00641-10 – Adjust the footrest bracket to the desired position. M00623-01 –  Mount and tighten screws Guideline Screw, front footrest bracket M8 25 Nm Loctite ® 243™ (18.4 lbf ft) M00641-10...

  • Page 77: Checking The Basic Position Of The Shift Lever

    ERGONOMICS – Mount the rider footrest with spring  and pin  Pliers for footrest spring (58429083000) –   Mount washer and cotter pin M00642-10 – Position the foot brake lever. –  Mount and tighten screw Guideline Screw, ball joint of push rod 10 Nm Loctite ®...

  • Page 78: Adjusting The Basic Position Of The Shift Lever

    ERGONOMICS – Sit on the vehicle in the riding position and determine distance  between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in) edge of boot »...

  • Page 79: Adjusting The Basic Position Of The Foot Brake Lever

    ERGONOMICS – 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. The shift lever must not come into contact with any other vehicle components during the shift procedure.
  • Page 80 ERGONOMICS – Mount and tighten screw  Guideline Screw, ball joint of push rod 10 Nm Loctite ® 243™ on foot brake cylinder (7.4 lbf ft) –  Attach spring...

  • Page 81: Preparing For Use

    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 82: 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 and Warranty Booklet at vehicle handover.

  • Page 83: Loading The Vehicle

    PREPARING FOR USE Info If the maximum engine speed is exceeded before the first service, the shift warning light flashes. 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.
  • Page 84 PREPARING FOR USE Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload. – Adapt your speed according to your payload. 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.

  • Page 85: Riding Instructions

    RIDING INSTRUCTIONS 10.1 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 86: Starting

    RIDING INSTRUCTIONS 10.2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 87: Starting Off

    RIDING INSTRUCTIONS – Press the electric starter button Info Do not press the electric starter button until the combination instrument func- tion check is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 88 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
  • Page 89 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.
  • Page 90 Contact an authorized KTM workshop. – If the engine warning lamp lights up during a trip, please contact an authorized KTM workshop as soon as possible. Info From the flash rhythm you can deduce a two-digit number, the so-called blink code.

  • Page 91: Applying The Brakes

    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 92 RIDING INSTRUCTIONS Warning Danger of accidents Greater stopping distance due to ABS. – Braking should be appropriate to the driving situation and the road conditions. Warning Danger of accidents Very forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents Vehicle rollover –...

  • Page 93: Stopping, Parking

    RIDING INSTRUCTIONS – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over-rev the engine. In this way, you have to brake far less and the brakes do not overheat. 10.6 Stopping, parking Warning...

  • Page 94: Transport

    RIDING INSTRUCTIONS Note Material damage Damage and destruction of components from excessive load. – The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when it is resting on the center stand. The center stand or the frame may become damaged and the motorcycle may fall over. –...

  • Page 95: Refueling

    RIDING INSTRUCTIONS 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 96 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 97: Service Schedule

    Every 30,000 km (18,600 mi) Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ○ ● ● ● ● Read out the trouble code memory using the KTM diagnostics tool. ● ● ● ● Check the fuel pressure. ○ ●...
  • Page 98 SERVICE SCHEDULE Every two years Every year Every 30,000 km (18,600 mi) Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ● ● Clean the dust boots of the fork legs. ● ● ● ● Check the chain, rear sprocket and engine sprocket. ( p.

  • Page 99: Recommended Work

    ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval 11.3 Recommended work Every four years Every two years...
  • Page 100 SERVICE SCHEDULE Every four years Every two years Every year Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ● ● ● ● Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.

  • Page 101: Suspension Setting

    SUSPENSION SETTING 12.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to the riding style and the payload. Info  The recommendations for the suspension setting are shown in table . The table is found on the left inside cover of the fuel tank.

  • Page 102: Adjusting The Rebound Damping Of The Fork

    SUSPENSION SETTING Guideline Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 12.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. –...

  • Page 103: Adjusting The Spring Preload Of The Fork

    SUSPENSION SETTING Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 12.4 Adjusting the spring preload of the fork –  Turn adjusting screws counterclockwise all the way.

  • Page 104: Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 105: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 106: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 107: Adjusting The Spring Preload Of The Shock Absorber

    Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 108 SUSPENSION SETTING – Turn handwheel  counterclockwise as far as it will go. – Turn it clockwise by the number of turns corresponding to the shock absorber type and use. Guideline Spring preload Comfort 4 turns Standard 4 turns Sport 4 turns S00950-10 Full payload...

  • Page 109: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 13.1 Raising the vehicle with the center stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Material damage Damage and destruction of components from excessive load. –...

  • Page 110: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Make sure that the steering is unlocked. – Move the vehicle forward with both hands on the handlebar. – While the vehicle tips off of the center stand, activate the front brake to stop the vehi- cle from rolling away.

  • Page 111: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 13.4 Mounting the seat –  Hook catch of the seat onto the fuel tank and lower the rear while pushing it for- ward. 0 0 2 0 0 1 –  Insert locking pin into the lock housing and push down the rear of the seat until the locking pin engages with a click.

  • Page 112: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 13.6 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 113: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 222) – After drying, apply chain spray. Chain lube for road use ( p.

  • Page 114: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Shift the transmission to idle – In the area in front of the chain guide, push the chain up and determine chain ten-  sion Info  The upper part of the chain must be taut.
  • Page 115 SERVICE WORK ON THE CHASSIS Main work –  Loosen nut – Loosen nuts  –  Adjust the chain tension by turning the adjusting screws on the left and right. Guideline Chain tension 40… 45 mm (1.57… 1.77 in) ...

  • Page 116: Checking The Chain, Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 13.9 Checking the chain, rear sprocket and engine sprocket Preparatory work – Raise the vehicle with the center stand. ( p. 107) Main work – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: –...
  • Page 117 SERVICE WORK ON THE CHASSIS – Shift the transmission to idle –  Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) –  Measure distance of 18 chain rollers on the upper part of the chain. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 118 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear at the cutout. Info  When the chain sliding guard is new, the rivets are half visible at the bottom  edge of the recess. » When the rivets of the chain are no longer visible at the bottom edge of the recess of the chain sliding guard: –...

  • Page 119: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 13.10 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

  • Page 120: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 121: Removing The Bottom Triple Clamp Cover

    SERVICE WORK ON THE CHASSIS – Check the steering head bearing and adjust if necessary. Finishing work – Remove the vehicle from the center stand. ( p. 107) 13.12 Removing the bottom triple clamp cover –  Remove screws – ...

  • Page 122: Installing The Bottom Triple Clamp Cover

    SERVICE WORK ON THE CHASSIS 13.13 Installing the bottom triple clamp cover –  Plug in connectors of the horn. –  Attach temperature sensor M00558-11 –  Position the triple clamp cover –  Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) M00557-11...

  • Page 123: Removing The Front Side Cover

    SERVICE WORK ON THE CHASSIS 13.14 Removing the front side cover –  Remove screw S00953-10 –  Remove screws –  Remove side cover – Repeat the operation on the opposite side. 307816-10...

  • Page 124: Installing The Front Side Cover

    SERVICE WORK ON THE CHASSIS 13.15 Installing the front side cover –  Position the side cover in the area under the tank cover. 307817-10 –   Attach catch of the side cover to bracket and position on the fuel tank. S00954-10...

  • Page 125: Removing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS – Mount and tighten screw  Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) S00953-11 –  Mount and tighten screws Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) – Repeat the operation on the opposite side. 307816-11 13.16 Removing the mask spoiler...
  • Page 126 SERVICE WORK ON THE CHASSIS Main work –  Remove screw 307823-10 –  Remove screw S00955-10 –  Loosen holding lug from the inside cover. 307825-10...
  • Page 127 SERVICE WORK ON THE CHASSIS – Remove the mask spoiler laterally from the supports. 307828-10 –  Pull the mask spoiler upward from bracket 307826-10 –  Disconnect plug-in connector – Remove the mask spoiler with the turn signal. – Repeat the operation on the opposite side.

  • Page 128: Installing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS 13.17 Installing the mask spoiler Main work –  Connect plug-in connector 307827-11 –  Position the mask spoiler in bracket Info Ensure that the turn signal cable is placed correctly. 307826-11...
  • Page 129 SERVICE WORK ON THE CHASSIS – Press the mask spoiler laterally into the supports. 307828-11 –  Position holding lug in the drill hole. 307825-10 –  Mount and tighten screw Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) S00955-11...

  • Page 130: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS – Mount and tighten screw  Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) – Repeat the operation on the opposite side. 307823-11 Finishing work – Install the tank cover. ( p. 131) –...

  • Page 131: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 13.19 Installing the front fender – Position the fender. Info Pay attention to the routing of the brake lines and the cable. –  Mount and tighten screws Guideline Screw, fender M5x12 3.5 Nm (2.58 lbf ft) M01387-11 –...
  • Page 132 SERVICE WORK ON THE CHASSIS – Remove screw  –  Remove screw M00628-10 –  Remove screw M00629-10 – Raise the tank cover at the rear and remove it in a forward direction. M00630-01...

  • Page 133: Installing The Tank Cover

    SERVICE WORK ON THE CHASSIS 13.21 Installing the tank cover Main work – Position the tank cover. Info Note the sealing lip. –  Mount and tighten screw Guideline Screw, cover part 3.5 Nm M00629-11 (2.58 lbf ft) –  Mount and tighten screw Guideline Screw, cover part...

  • Page 134: Removing The Wind Shield

    SERVICE WORK ON THE CHASSIS – Mount and tighten screw  Guideline Screw, cover part 6 Nm (4.4 lbf ft) –  Mount and tighten screw Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) M00627-11 Finishing work – Install the front side cover. ( p.

  • Page 135: Installing The Wind Shield

    SERVICE WORK ON THE CHASSIS 13.23 Installing the wind shield –  Position wind shield –  Mount and tighten screws Guideline Screw, wind shield 3.5 Nm (2.58 lbf ft) S00956-11 13.24 Removing the engine guard –   Remove screws and engine guard S00331-10...

  • Page 136: Installing The Engine Guard

    SERVICE WORK ON THE CHASSIS 13.25 Installing the engine guard –   Position engine guard . Mount and tighten screws Guideline Screw, engine guard 10 Nm (7.4 lbf ft) S00331-11...

  • Page 137: Brake System

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.
  • Page 138 BRAKE SYSTEM Warning Danger of accidents Vehicle rollover – It is not always possible to prevent vehicle rollover in extreme riding situations (e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your driving ability.

  • Page 139: Checking The Brake Discs

    The MSC is a software-based extension since all required hardware components are already present. 14.2 Checking the brake discs Warning 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.)

  • Page 140: Checking The Brake Fluid Level Of The Front Brake

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 141: Adding Front Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 142 BRAKE SYSTEM 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 use 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.

  • Page 143: Checking The Front Brake Linings

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 144: Adding Rear Brake Fluid

    BRAKE SYSTEM Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...
  • Page 145 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 146: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...
  • Page 147 BRAKE SYSTEM – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in)  Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »...

  • Page 148: Wheels, Tires

    WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the vehicle with the center stand. ( p. 107) Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. –...
  • Page 149 WHEELS, TIRES – Loosen screw  by several rotations. –  Loosen screws –  Press on screw to push the wheel spindle out of the axle clamp. –  Remove screw Warning Danger of accidents Reduced braking efficiency due to damaged brake discs. –...

  • Page 150: Installing The Front Wheel

    WHEELS, TIRES 15.2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. –...
  • Page 151 WHEELS, TIRES 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. –   Clean and grease screw and wheel spindle Long-life grease ( p.

  • Page 152: Removing The Rear Wheel

    WHEELS, TIRES – Position the wheel speed sensor  in the drill hole. –  Mount and tighten screw Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Remove the vehicle from the center stand. ( p. 107) V00006-11 –...
  • Page 153 WHEELS, TIRES Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. M00612-01 –   Remove screw and pull wheel speed sensor out of the hole. S00277-10 –...

  • Page 154: Installing The Rear Wheel

    WHEELS, TIRES – Pull out wheel spindle  only far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Take the chain off of the rear sprocket  and place it on chain sprocket guard Warning Danger of accidents Reduced braking effect caused by damaged brake discs.
  • Page 155 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. –   Clean and grease shaft seal ring and contact surface of the spacer. Long-life grease ( p.
  • Page 156 WHEELS, TIRES – Push the wheel spindle in all the way and mount chain adjuster  and nut  Info   Mount chain adjusters in the same position. – Make sure that the chain adjusters are fitted correctly on the adjusting screws. Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right ...

  • Page 157: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES 15.5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. The rubber dampers wear out dur- ing operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. Preparatory work –...

  • Page 158: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 159: 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 160: Checking Spoke Tension

    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 can easily cause lateral or radial runout on the wheel. More spokes loosen in a short period.
  • Page 161 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound is a function of the spoke length and spoke diame- ter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 162: Electrical System

    ELECTRICAL SYSTEM 16.1 daytime running light The daytime running light/parking light is integrated in the main headlight. The daytime running light (DRL) can be switched on when visibility conditions are good. Activate the daytime running light in the combination instrument. Control is provided by the brightness sensor in the combination instrument.
  • Page 163 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 108) Main work –  Pull locking mechanism in the direction of the arrow. –  Fold open cover M00632-10 –...

  • Page 164: Installing The Battery

    ELECTRICAL SYSTEM 16.3 Installing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 165: Recharging The Battery

    ELECTRICAL SYSTEM Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) –  Close the cover and push down slightly. The cover engages with an audible click. M00632-11 Finishing work – Mount the seat. ( p. 109) – Set the time and date. 16.4 Recharging the battery Warning...
  • Page 166 The battery is maintenance-free, i.e., the acid level does not have to be checked. If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage may damage electronic components. Charge the battery according to the instructions on the battery housing.
  • Page 167 ELECTRICAL SYSTEM Main work –  Pull locking mechanism in the direction of the arrow. – Fold open cover  M00632-10 –  Disconnect negative cable of the battery to avoid damage to the motorcycle's elec- tronics. M00562-10 – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) Info You can also use the battery charger to test the open-circuit voltage and start...
  • Page 168 ELECTRICAL SYSTEM – Switch off the battery charger after charging and disconnect from the battery. Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly when the 3 months motorcycle is not in use –...

  • Page 169: Changing The Main Fuse

    ELECTRICAL SYSTEM 16.5 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 170 ELECTRICAL SYSTEM – Remove the faulty main fuse  Info  A defective fuse is indicated by a burned-out fuse wire  A reserve fuse is located in the starter relay. The main fuse protects all power consumers of the vehicle. –...

  • Page 171: Changing The Fuses In The Fuse Box

    ELECTRICAL SYSTEM 16.6 Changing the fuses in the fuse box Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work –...
  • Page 172 ELECTRICAL SYSTEM – Check the fuses. Info  A defective fuse is indicated by a burned-out fuse wire – Remove the defective fuse. Guideline Fuse res - 10 A - spare fuses Fuse 1 - 10 A - power supply for control units and components V00001-10 Fuse 2 - 10 A - socket (ACC1) Fuse 3 - 25 A - ABS hydraulic unit...

  • Page 173: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 16.7 Removing the headlight mask with the headlight Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 108) – Remove the front side cover. ( p. 121) – Remove the tank cover.

  • Page 174: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 16.8 Refitting the headlight mask with the headlight Main work –  Connect plug-in connector of the headlight. – Check that the lighting is functioning properly. – Position the headlight mask. S00294-11 –  Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft)

  • Page 175: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM 16.9 Changing the low beam bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 176: Changing The High Beam Bulb

    ELECTRICAL SYSTEM – Plug connector  into the new headlight bulb. Low beam (H11/socket PGJ19-2) ( p. 212) –  Position headlight bulb into the bulb socket and turn it all the way clockwise. The headlight bulb is locked into the bulb socket. S00298-10 Finishing work –...
  • Page 177 ELECTRICAL SYSTEM – Remove the seat. ( p. 108) – Remove the front side cover. ( p. 121) – Remove the tank cover. ( p. 129) – Remove the mask spoiler. p. 123) – Remove the wind shield. ( p. 132) –...

  • Page 178: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Install the mask spoiler. p. 126) – Install the tank cover. ( p. 131) – Install the front side cover. ( p. 122) – Mount the seat. ( p. 109) – Check the headlight setting. ( p. 177) 16.11 Changing the turn signal bulb Note...

  • Page 179: Checking The Headlight Setting

    ELECTRICAL SYSTEM Info   Hook in projection at recess – Insert the screw and first turn it counterclockwise until it engages in the thread. Tighten the screw slightly. 16.12 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the height of the center of the low beam headlight.

  • Page 180: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 16.13 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 177) – Remove the bottom triple clamp cover. ( p. 119) Main work –  Turn adjusting screw to adjust the headlight range. Info Turn clockwise to increase the headlight range;...

  • Page 181: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM 16.14 Activating/deactivating the ignition key Info The orange programming key must only be used for activating and deactivating! If a black ignition key is lost or needs to be replaced, the individual black ignition keys need to be enabled or disabled using the orange programming key.
  • Page 182 ELECTRICAL SYSTEM – Switch off the ignition by turning the black ignition key to the position OFF – Remove the black ignition key. – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position The immobilizer indicator lamp flashes according to the number of func- tional black ignition keys including the orange programming key.
  • Page 183 ELECTRICAL SYSTEM – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position Immobilizer indicator lamp lights up. – Switch off the ignition by turning the orange programming key to the OFF position –...
  • Page 184 ELECTRICAL SYSTEM – If the last black ignition key was activated, insert the orange programming key into the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position The immobilizer indicator lamp flashes according to the number of func- tional black ignition keys including the orange programming key.
  • Page 185 ELECTRICAL SYSTEM Info After the fourth black ignition key has been activated, programming is fin- ished.

  • Page 186: Cooling System

    COOLING SYSTEM 17.1 Checking the coolant level in the compensating tank 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 187: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM – Correct the coolant level in the compensating tank. ( p. 185) 17.2 Correcting the coolant level in the compensating tank 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 188 COOLING SYSTEM Main work –  Remove cover of the compensating tank. M00636-10 – Add coolant until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX. Coolant ( p. 219) – Mount the cover of the compensating tank. M00637-01 Finishing work –...

  • Page 189: Tuning The Engine

    TUNING THE ENGINE 18.1 "Drive Mod" Possible states SPORT – Homologated performance with very direct response; the traction control • allows greater slip on the rear wheel STREET – Homologated performance with balanced response; the traction control • allows normal slip on the rear wheel RAIN –...
  • Page 190 TUNING THE ENGINE Info When motorcycle traction control is active, the TC lamp flashes. When motorcycle traction control is switched off, the TC lamp lights up.

  • Page 191: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 19.1 Checking the engine oil level Info Oil consumption depends on the riding style and the operating conditions. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...

  • Page 192: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 19.2 Changing the engine oil and oil filter, cleaning the oil screens 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.
  • Page 193 SERVICE WORK ON THE ENGINE – Remove screws  . Remove oil filter cover  with the O-ring. S00334-10 –  Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...
  • Page 194 SERVICE WORK ON THE ENGINE – Mount and tighten screws  Guideline Remaining engine screws 6 Nm (4.4 lbf ft) S00334-11 –   Thoroughly clean magnets and oil screens of the oil drain plugs. 100773-12 –  Mount and tighten oil drain plugs with the magnets, O-rings, and oil screens.
  • Page 195 SERVICE WORK ON THE ENGINE – Add the oil quantity in two separate operations. Engine oil 3.60 l (3.8 qt.) Outside Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 219) Outside Engine oil (SAE temperature: 5W/40) ( p.

  • Page 196: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the screw plug and add the remaining engine oil to the upper marking  the engine oil level viewer. – Mount the screw plug. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
  • Page 197 Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 220) S00329-10 Info In order to achieve optimal engine performance, it is not advisable to mix differ- ent engine oils. KTM recommends changing the engine oil. – Mount the screw plug.
  • Page 198 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 199: Cleaning, Care

    CLEANING, CARE 20.1 Cleaning motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 200 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the closure of the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys- tem.

  • Page 201: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p. 223) – Oil the ignition/steering lock, tank lock, and seat lock. Universal oil spray ( p. 223) 20.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads.
  • Page 202 CLEANING, CARE – Clean the chain. ( p. 110)

  • Page 203: Storage

    STORAGE 21.1 Storage Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload).

  • Page 204: Preparing For Use 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 the exhaust system to rust.

  • Page 205: Troubleshooting

    Recharge the battery. p. 163) – Check the quiescent current. – Safety start system is faulty Read out the fault memory using the KTM diag- nostics tool. – ICU is not enabled Activate the ICU. – CAN bus communication error Read out the fault memory using the KTM diag- nostics tool.
  • Page 206 Faults Possible cause Action – Engine turns but does not start Fault in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Fuel quality is insufficient Add suitable fuel. – Engine dies during the trip Lack of fuel Refuel.

  • Page 207: Technical Data

    TECHNICAL DATA 23.1 Engine Design 2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled Displacement 1,195 cm³ (72.92 cu in) Stroke 69 mm (2.72 in) Bore 105 mm (4.13 in) Compression ratio 12.5:1 Idle speed 1,300… 1,500 rpm Control DOHC, 4 valves per cylinder, chain-driven Valve - valve plate diameter Intake 42 mm (1.65 in)

  • Page 208: Engine Tightening Torques

    TECHNICAL DATA 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug Inside spark plug NGK LKAR9BI9...
  • Page 209 TECHNICAL DATA Screw, bearing shells retaining bracket 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, engine oil level viewer 4 Nm (3 lbf ft) Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, pulse generator 6 Nm (4.4 lbf ft) –...

  • Page 210: Nm (3 Lbf Ft)

    TECHNICAL DATA – Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite ® 243™ – Stud, chain shaft 8 Nm (5.9 lbf ft) Loctite ® 243™ Nozzle 100 M6x0.75 4 Nm (3 lbf ft) –...

  • Page 211: Capacities

    TECHNICAL DATA – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) – Spark plug M10x1 11 Nm (8.1 lbf ft) Cylinder head screw M11x1.5 Tightening sequence: Lubricated with engine oil Using a crisscross pattern Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3...

  • Page 212: Coolant

    TECHNICAL DATA Engine oil 3.60 l (3.8 qt.) Outside temperature: < 0 °C Engine oil (SAE 5W/40) (< 32 °F) p. 220) 23.3.2 Coolant Coolant 2.40 l (2.54 qt.) Coolant ( p. 219) 23.3.3 Fuel Total fuel tank capacity, approx. 23 l (6.1 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 213: Electrical System

    TECHNICAL DATA Front 320 mm (12.6 in) Rear 267 mm (10.51 in) Brake discs - wear limit Front 4 mm (0.16 in) Rear 4.5 mm (0.177 in) Tire air pressure, solo/with passenger/full payload Front: with cold tires 2.4 bar (35 psi) Rear: with cold tires 2.9 bar (42 psi) Secondary drive ratio...

  • Page 214: Tires

    Rear tires 90/90 - 21 M/C 54T M+S TL 150/70 B 18 M/C 70Q TL Continental TKC 80 Twinduro Continental TKC 80 Twinduro Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.8N.25 Fork...
  • Page 215 TECHNICAL DATA Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring preload - Preload Adjuster Comfort 2 turns Standard 5 turns Sport 5 turns Full payload...

  • Page 216: Shock Absorber

    TECHNICAL DATA 23.8 Shock absorber Shock absorber article number 15.18.7P.25 Shock absorber WP Performance Systems 4618 BAVP DCC PA Compression damping, low-speed Comfort 15 clicks Standard 10 clicks Sport 8 clicks Full payload 8 clicks Compression damping, high-speed Comfort 1.5 turns Standard 1.5 turns Sport...

  • Page 217: Chassis Tightening Torques

    TECHNICAL DATA Medium (standard) 180 N/mm (1,028 lb/in) Spring length 205 mm (8.07 in) Gas pressure 10 bar (145 psi) Riding sag 55 mm (2.17 in) Static sag 25 mm (0.98 in) Fitted length 408 mm (16.06 in) Shock absorber fluid ( p.
  • Page 218 TECHNICAL DATA – Screw, wind shield 3.5 Nm (2.58 lbf ft) – Spoke nipple 5 Nm (3.7 lbf ft) – Ground fitting on frame 6 Nm (4.4 lbf ft) – Nut, ABS unit fixation 8 Nm (5.9 lbf ft) – Remaining chassis nuts 10 Nm (7.4 lbf ft) –...

  • Page 219: Nm (4.4 Lbf Ft) Loctite

    TECHNICAL DATA Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, retaining bracket, angle sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, voltage regulator 6 Nm (4.4 lbf ft) – Screw, wheel speed sensor, front 10 Nm (7.4 lbf ft) –...
  • Page 220 TECHNICAL DATA Screw, side stand 35 Nm (25.8 lbf ft) Loctite ® 243™ Screw, side stand bracket 45 Nm (33.2 lbf ft) Loctite ® 243™ – Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) – Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Screw, bottom shock absorber M14x1.5...

  • Page 221: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 222 SUBSTANCES Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Fully synthetic engine oil Recommended supplier Motorex ® – Power Synt 4T Engine oil (SAE 5W/40) Standard/classification –...
  • Page 223 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 224) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding proper- ties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 224: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
  • Page 225 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 226: 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 227: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces ATIR Automatic Turn Indicator Reset Software, which automatically switches the indicator off according to a time or travel distance counter Daytime Running Light Light, which enhances the visibility of the vehicle during the day but is not focused, and in contrast to low beam does not illuminate...

  • Page 228: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 229: Lisy Of Symbols

    LISY OF SYMBOLS 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low. 29.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention.
  • Page 230 LISY OF SYMBOLS The left turn signal lamp flashes green simultaneously with the turn signal – The left turn signal is switched on. The idle indicator lamp lights up green – The transmission is shifted to idle. The right turn signal lamp flashes green simultaneously with the turn signal – The right turn signal is switched on.

  • Page 231: Index

    INDEX INDEX Capacity ABS ........135 coolant .
  • Page 232 INDEX "General Info" ....... . 57 "Heat Grips" ....... . . 67 Electric starter button .
  • Page 233 INDEX Footrests Headlight adjusting ........73 daytime running light .
  • Page 234 INDEX checks and maintenance measures when preparing for use . 83 Protective clothing ....... 20 Main fuse changing .
  • Page 235 INDEX basic position, checking ......75 Storage ........201 Shifting .
  • Page 236 INDEX installing ........133 Tire condition checking ........156 removing .
  • Page 237 *3213390en* 3213390en 09/2015 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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