KTM 1190 Adventure R Owner's Manual
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KTM 1190 Adventure R Owner's Manual

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2014
OWNER'S MANUAL
1190 Adventure R USA
Art. no. 3213108en

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Summary of Contents for KTM 1190 Adventure R

  • Page 1 2014 OWNER'S MANUAL 1190 Adventure R USA Art. no. 3213108en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 DEAR KTM CUSTOMER ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS View of vehicle, rear right side (vehicle differs TABLE OF CONTENTS MEANS OF REPRESENTATION ........8 slightly from photo) ..........26 Symbols used ............8 SERIAL NUMBERS ............28 Formats used............8 Chassis number ..........28 SAFETY ADVICE.............. 9 Type label ............
  • Page 6 TABLE OF CONTENTS 6.12 Opening the storage compartment ....... 42 7.9.10 "MTC/ABS" ............ 58 6.13 Closing the storage compartment......42 7.9.11 "Drive Mode" ..........58 6.14 Seat lock............43 7.9.12 Menu overview..........60 6.15 Tool set............. 43 7.9.13 "Language" ............ 61 6.16 Grab handles .............
  • Page 7 TABLE OF CONTENTS PREPARING FOR USE........... 77 12.9 Adjusting the spring preload of the shock absorber............103 Advice on first use ..........77 13 SERVICE WORK ON THE CHASSIS....... 105 Running in the engine ........78 13.1 Raising the vehicle with the center stand ... 105 Loading the vehicle ..........
  • Page 8 TABLE OF CONTENTS 14 BRAKE SYSTEM ............131 16.8 Refitting the headlight mask with the headlight............167 14.1 ABS/antilock brake system........ 131 16.9 Changing the low beam bulb ......168 14.2 Checking the brake discs ........133 16.10 Changing the high beam bulb......169 14.3 Checking the brake fluid level of the front brake ..............
  • Page 9 TABLE OF CONTENTS 23 TECHNICAL DATA............200 23.1 Engine ............200 23.2 Engine tightening torques ......... 201 23.3 Capacities ............205 23.3.1 Engine oil ........... 205 23.3.2 Coolant ............205 23.3.3 Fuel ............205 23.4 Chassis ............205 23.5 Electrical system..........207 23.6 Tires ...............

  • 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: 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 12: Degrees Of Risk And Symbols

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

  • Page 14: Overview Of Labels

    SAFETY ADVICE Overview of labels 500295-10...
  • Page 15 SAFETY ADVICE Information on suspension tuning Canada type label Information on starting up Information on emission control Information on chain tension Information on noise emission USA type label Technical Information Information on suspension tuning 500296-01...
  • Page 16 SAFETY ADVICE 500297-01 Canada type label Information on starting up 700210-01...
  • Page 17 SAFETY ADVICE 500299-01 Information on emission control Information on chain tension 500304-01...
  • Page 18 SAFETY ADVICE 500301-01 Information on noise emission 500302-01 USA type label...

  • Page 19: Reporting Safety Defects

    Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA 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 20: Operating Noise Warning

    Otherwise, the owner may become subject to penalties under the applicable ordinances. Consumer rights Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553...

  • Page 21: Safe Operation

    The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • 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: Owner's Manual

    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 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 Service and Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 25: Figures

    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 side (vehicle differs slightly from photo) 500293-10...
  • Page 27 VIEW OF VEHICLE Socket for electrical accessories ( p. 38) Clutch lever ( p. 32) Tool set ( p. 43) Grab handles ( p. 44) Luggage rack plate ( p. 44) Seat lock ( p. 43) Passenger footrests ( p. 45) Center stand ( 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) 500294-10...
  • Page 29 VIEW OF VEHICLE Combination switch ( p. 33) Filler cap Fork compression adjustment Fork rebound adjustment Emergency OFF switch ( p. 36) Electric starter button ( p. 37) 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. 500306-10 Type label Type label USA is affixed to the frame behind the steering head at the top right. 500305-10...

  • Page 31: Key Number

    SERIAL NUMBERS Type label Canada is affixed to the frame behind the steering head at the top left. 500307-10 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. S00261-10 Fork part number The fork part number is stamped on the inner side of the fork stub. S00306-10...

  • Page 33: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber. S00264-10...

  • 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. S00214-10 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 Switch 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 – Light switch in position .

  • 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. Button is the SET button.

  • Page 38: Horn Button

    CONTROLS 6.4.6 Horn button The horn button is fitted on the combination switch on the left. Possible states • Horn button in basic position. pressed – The horn is operated in this position. • Horn button S00218-10 Switch on the right side of the handlebar 6.5.1 Emergency OFF switch The emergency OFF switch...

  • Page 39: Electric Starter Button

    CONTROLS 6.5.2 Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position. is pressed – In this position, the electric starter is actuated. • Electric starter button S00221-10 Ignition/steering lock The ignition/steering lock...

  • Page 40: Immobilizer

    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. Socket for electrical accessories Socket for electrical accessories is fitted to the left of the combination instrument.

  • Page 41: Opening The Filler Cap

    CONTROLS 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 42: 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 S00227-10 6.10 Closing the filler cap –...

  • Page 43: Fuel Cocks

    CONTROLS – Press down the filler cap and turn back ignition key until the fuel tank lock locks. 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 44: Opening The Storage Compartment

    CONTROLS 6.12 Opening the storage compartment – Press button in the direction of the arrow and lift the cover at the same time. S00226-10 6.13 Closing the storage compartment – Press down cover until the lock engages audibly. S00226-11...

  • Page 45: Seat Lock

    CONTROLS 6.14 Seat lock The seat lock is located on the left side of the vehicle. It can be unlocked using the ignition key. S00238-10 6.15 Tool set The tool set is located in the storage compartment under the seat. S00235-10...

  • Page 46: Grab Handles

    CONTROLS 6.16 Grab handles The passenger can hold onto grab handles during the trip. S00236-10 6.17 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.

  • Page 47: Passenger Footrests

    CONTROLS 6.18 Passenger footrests 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. • S00234-10 6.19 Shift lever The shift lever is fitted on the left side of the engine.

  • Page 48: Side Stand

    CONTROLS The gear positions can be seen in the figure. The idle position is between the first and second gears. S00232-10 6.20 Side stand The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use.

  • Page 49: Center Stand

    CONTROLS 6.21 Center stand In addition to the side stand, the vehicle is equipped with a center stand S00258-10...

  • Page 50: Combination Instrument

    COMBINATION INSTRUMENT Overview Matrix display ( p. 49) Tachometer Shift warning light ( p. 52) Segment display Indicator lamps ( p. 50) 401800-10 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 51: 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. 53) is due. If the General warning lamp lights up among the indicator lamps ( p.

  • Page 52: 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/flashes red – Status or error mes- sage for immobilizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low.

  • Page 53: 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. Traction control – Traction control is not available. Visit an authorized KTM 401850-01 workshop.

  • Page 54: 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 "Warnings" menu.

  • Page 55: Service Display

    COMBINATION INSTRUMENT 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 applies. The exact service intervals can be found in the service schedule. 401821-01 Matrix display menu 7.9.1...

  • Page 56: 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 57: 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 58: Set Favorites

    COMBINATION INSTRUMENT 7.9.6 "Set Favorites" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Set Favorites" menu appears on the matrix dis- play. Pressing the SET button opens the menu. – Press the UP or DOWN button to select the menu. Press the SET button to set the menu for quick selection.

  • Page 59: Warnings

    COMBINATION INSTRUMENT 7.9.8 "Warnings" Condition • Message or warning – Press the UP or DOWN button until the "Warnings" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the UP or DOWN button to navigate through the warnings. In the "Warnings"...

  • Page 60: Mtc/Abs

    COMBINATION INSTRUMENT 7.9.10 "MTC/ABS" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "MTC/ABS" menu appears on the matrix display. In the "MTC/ABS" menu, "MTC" and "ABS" can be switched off. In "ABS mode", a choice can be made between "Road" and "Offroad". Info After the ignition is switched on, traction control and ABS are enabled again.

  • Page 62: Menu Overview

    COMBINATION INSTRUMENT 7.9.12 Menu overview 401992-01...

  • Page 63: Language

    COMBINATION INSTRUMENT KTM start screen Menu buttons "Favorites" "Trip 1" "Trip 2" "General Info" "TPMS" (optional) "Set Favorites" "Settings" "Warnings" (only active if messages are present) "Heat Grip" (optional) "MTC/ABS" "Drive Mode" 7.9.13 "Language" Condition • The vehicle is stationary.

  • Page 64: 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 65: Volume

    COMBINATION INSTRUMENT 7.9.16 "Volume" 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 "Volume" is highlighted in black on the matrix dis- play.

  • Page 66: 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 67: Drl

    COMBINATION INSTRUMENT 7.9.20 "DRL" 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 "DRL" is highlighted in black on the matrix display. Pressing the SET button again switches daytime running light on or off.

  • Page 68: Quick Shift

    COMBINATION INSTRUMENT 7.9.22 "Quick Shift" 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. – The "Quick Shift" function cannot be activated. Info This function is not available in this model.

  • Page 69: 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 70: Adjusting The Wind Shield

    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 cables and wiring are positioned correctly. – Position the handlebar clamps. Mount and evenly tighten screws Guideline Screw, handlebar clamp 20 Nm...
  • Page 71 ERGONOMICS – Move the wind shield in the required position. S00247-10 – Lock clamping lever by pushing in the direction of the arrow. S00342-11...

  • Page 72: Adjusting The Basic Setting Of The Clutch Lever

    ERGONOMICS Adjusting the basic setting of the clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

  • Page 73: Rider Footrests

    ERGONOMICS Rider footrests The rider footrests can be mounted in one of two positions. Possible states • Rider footrests, low • Rider footrests, high S00230-10 Adjusting the footrests Info The operations are the same for the left and right sides. –...
  • Page 74 ERGONOMICS – Remove screws S00249-10 – Adjust the footrest bracket to the desired position. S00250-10 – Mount and tighten screws Guideline Screw, front footrest bracket M8 25 Nm Loctite ® 243™ (18.4 lbf ft) S00249-10...

  • Page 75: Foot Brake Lever

    ERGONOMICS – Mount the rider footrest with spring and pin Pliers for footrest spring (58429083000) – Mount washer and cotter pin S00251-10 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. S00233-10 Adjusting the basic position of the foot brake lever Warning...
  • Page 76 ERGONOMICS – Disconnect spring – Loosen nut – Remove screw – To adjust the basic position of the foot brake lever to individual requirements, turn ball joint accordingly. Info The range of adjustment is limited. The screw must be screwed into the ball joint by at least 5 turns. S00283-10 –...

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

    ERGONOMICS 8.10 Checking the basic position of the shift lever – 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 78 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 79: 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 80: 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 81: 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 82 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 83: 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 84: 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 85: 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 86 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 87 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 88 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 89: 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 90 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 Excessively forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents Vehicle rollover –...

  • Page 91: 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 92: 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 93: 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 94 – 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 95: 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 96 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) ○ ● ● ● ● Check the shock absorber and fork for leaks. Perform a fork service and shock absorber service as needed and depending on how the vehicle will be used.
  • Page 97 Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● Check the CO adjustment with the KTM diagnostics tool. ○ ● ● ● ● Make the service entry in the KTM DEALER.NET and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 98: Recommended Work

    SERVICE SCHEDULE 11.3 Recommended work Every four years Every two years Every year Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ○ ● Check/clean the oil nozzle for clutch lubrication. ● Check the swingarm bearing. ● Check the wheel bearing for play. ○...

  • Page 99: 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. These adjustments are guidelines and should always be the basis for a suspension setting.

  • Page 100: 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 101: 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 102: 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 low-speed setting takes effect during the slow to normal compression of the shock absorber.

  • Page 103: Adjusting The High-Speed Compression Damping Of The Shock Absorber

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

  • Page 104: 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 105: 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 106 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 S00268-10 Full payload 16 turns...

  • Page 107: 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 108: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Unlock the steering and 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 109: 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 110: 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 111: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 13.7 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.

  • Page 112: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 13.8 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.
  • Page 113 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) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position in relation to reference marks...

  • Page 114: 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. 105) Main work – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: –...
  • Page 115 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 116 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear at the cutout. » If rivet of the chain is no longer visible at the lower edge of the recess of the chain sliding guard: – Change the chain sliding guard. –...

  • Page 117: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Guideline Screw, chain guide 5 Nm Loctite ® 243™ (3.7 lbf ft) Finishing work – Remove the vehicle from the center stand. ( p. 105) 13.10 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc.

  • Page 118: 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 119: Removing The Bottom Triple Clamp Cover

    SERVICE WORK ON THE CHASSIS – Check the steering head bearing and adjust if necessary. 13.12 Removing the bottom triple clamp cover – Remove screws – Plug out the horn. – Remove the triple clamp cover 202248-12 13.13 Installing the bottom triple clamp cover –...

  • Page 120: Removing The Front Side Cover

    SERVICE WORK ON THE CHASSIS 13.14 Removing the front side cover – Remove screw 307815-10 – Remove screws – Remove side cover – Repeat the operation on the opposite side. 307816-10...

  • Page 121: 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 and bracket of the side cover to the fuel tank and position the side cover.

  • Page 122: Removing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, cover part M5x12 3.5 Nm (2.58 lbf ft) 307815-11 – Mount and tighten screws Guideline Screw, cover part M5x12 3.5 Nm (2.58 lbf ft) – Repeat the operation on the opposite side. 307816-11 13.16 Removing the mask spoiler...
  • Page 123 SERVICE WORK ON THE CHASSIS Main work – Remove screw 307823-10 – Remove screw 307824-10 – Loosen holding lug from the inside cover. 307825-10...
  • Page 124 SERVICE WORK ON THE CHASSIS – Remove the mask spoiler laterally from the supports. 307828-10 – Pull the mask spoiler upward from bracket 307826-10 – Detach connector – Remove the mask spoiler with the turn signal. – Repeat the operation on the opposite side. 307827-10...

  • Page 125: Installing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS 13.17 Installing the mask spoiler Main work – Plug in connector 307827-11 – Position the mask spoiler in bracket Info Ensure that the turn signal cable is placed correctly. 307826-11...
  • Page 126 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) 307824-11...

  • Page 127: 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. 128) – Install the front side cover.

  • Page 128: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 13.19 Installing the front fender – Position the fender. Info Pay attention to where the brake lines are placed. – Mount and tighten screws Guideline Screw, fender M5x12 3.5 Nm (2.58 lbf ft) S00323-11 – Mount holder with the brake line on the fender.
  • Page 129 SERVICE WORK ON THE CHASSIS – Remove screw – Remove screw 307820-10 – Remove screw 307821-10 – Raise the tank cover at the rear and remove it in a forward direction. 307822-10...

  • Page 130: 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 M5x12 3.5 Nm 307821-11 (2.58 lbf ft) – Mount and tighten screw Guideline Screw, cover part 6 Nm (4.4 lbf ft)

  • Page 131: 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 M5x12 3.5 Nm (2.58 lbf ft) 307819-11 Finishing work – Install the front side cover. ( p.

  • Page 132: 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) S00259-11...

  • Page 133: Brake System

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.
  • Page 134 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 riding ability.

  • Page 135: Checking The 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 front and rear brake discs at multiple points on each brake...

  • Page 136: Checking The Brake Fluid Level Of The Front Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 137 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 138: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 139: Checking The Rear Brake Fluid Level

    (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.) Preparatory work –...

  • Page 140: Adding Rear 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 141 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 142: 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 143: Wheels, Tires

    WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the vehicle with the center stand. ( p. 105) Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. –...
  • Page 144 WHEELS, TIRES – Loosen screws – Unscrew screw about six turns and press your hand on the 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 145: 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 146 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 screw and wheel spindle –...

  • Page 147: Removing The Rear Wheel

    WHEELS, TIRES – Insert wheel speed sensor into the hole and position it. – Mount and tighten screw Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Remove the vehicle from the center stand. ( p. 105) S00313-11 – Pull the front brake and compress the fork forcefully a few times.
  • Page 148 WHEELS, TIRES Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. S00275-10 – Remove screw and pull wheel speed sensor out of the hole. S00277-10 – Remove nut .

  • Page 149: 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 150 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 151: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – Push the wheel spindle in all the way and mount chain adjuster and nut Info Mount chain adjusters in the same position. – Push the rear wheel forward so that the chain adjusters are in contact with the tension- ing screws, and tighten nut Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right...
  • Page 152 WHEELS, TIRES Preparatory work – Raise the vehicle with the center stand. ( p. 105) – Remove the rear wheel. p. 145) Main work – Check the rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: –...

  • Page 153: 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 154: 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 155: 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 156 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 157: 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 can be switched on when visibility conditions are good. Activate the daytime running light in the combination instrument. Control is provided by the bright- ness sensor in the combination instrument.
  • Page 158 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 106) Main work – Pull locking mechanism in the direction of the arrow. – Fold open cover S00302-10 – Disconnect negative cable of the battery.

  • Page 159: 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 160: Recharging The Battery

    ELECTRICAL SYSTEM – Connect both negative cables Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) – Fold down cover and let it lock by pushing down lightly. S00304-10 Finishing work – Mount the seat. ( p. 107) – Set the time and date. 16.4 Recharging the battery Warning...
  • Page 161 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 162 ELECTRICAL SYSTEM Main work – Pull locking mechanism in the direction of the arrow. – Fold open cover S00302-10 – Disconnect the negative cable of the battery to avoid damage to the motorcycle's electronics. 602677-11 – 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 open-circuit voltage and start potential of the battery, and to test the alternator.
  • Page 163 ELECTRICAL SYSTEM – Switch off and disconnect the battery charger after charging. 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 – Connect both negative cables Guideline Screw, battery terminal 4.5 Nm...

  • Page 164: 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 by-pass or repair fuses. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 165 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. – Install a new main fuse. Fuse (58011109130) ( p.

  • Page 166: 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 by-pass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work –...
  • Page 167 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 S00321-10 Fuse 2 - 10 A - socket (ACC1) Fuse 3 - 25 A - ABS hydraulic unit...

  • Page 168: 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. 106) – Remove the front side cover. ( p. 118) – Remove the tank cover.

  • Page 169: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 16.8 Refitting the headlight mask with the headlight Main work – Connect 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) S00293-11 Finishing work...

  • Page 170: 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 171: Changing The High Beam Bulb

    ELECTRICAL SYSTEM – Plug connector into the new headlight bulb. Low beam (H11/socket PGJ19-2) ( p. 207) – 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 172 ELECTRICAL SYSTEM – Remove the seat. ( p. 106) – Remove the front side cover. ( p. 118) – Remove the tank cover. ( p. 126) – Remove the mask spoiler. p. 120) – Remove the wind shield. ( p. 129) –...

  • Page 173: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Install the mask spoiler. p. 123) – Install the tank cover. ( p. 128) – Install the front side cover. ( p. 119) – Mount the seat. ( p. 107) – Check the headlight setting. ( p. 172) 16.11 Changing the turn signal bulb Note...

  • Page 174: 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 175: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 16.13 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 172) – Remove the bottom triple clamp cover. ( p. 117) Main work – Turn adjusting screw to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.

  • Page 176: 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 177 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 178 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 179 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 180 ELECTRICAL SYSTEM Info After the fourth black ignition key has been activated, programming is fin- ished.

  • Page 181: 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 182: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM – Correct the coolant level in the compensating tank. ( p. 180) 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 183 COOLING SYSTEM Main work – Remove cover of the compensating tank. S00325-10 – Add coolant until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX. Alternative 1 Coolant ( p. 214) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 184: Engine Tuning

    ENGINE TUNING 18.1 "Drive Mode" Possible states Sport – Homologated performance with very direct response; the traction control allows • greater slip on the rear wheel Street – Homologated performance with very direct response; the traction control • allows normal slip on the rear wheel RAIN –...
  • Page 185 ENGINE TUNING Info When traction control is active, the TC lamp flashes. When traction control is switched off, the TC lamp is lit.

  • Page 186: 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 187: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 19.2 Changing the engine oil and 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 188 SERVICE WORK ON THE ENGINE – Remove screws . Remove the 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. – Thoroughly clean the parts and sealing surface. S00335-10 –...
  • Page 189 SERVICE WORK ON THE ENGINE – Mount and tighten screws Guideline Remaining engine screws 6 Nm (4.4 lbf ft) S00334-11 – Thoroughly clean magnet and oil screen of the oil drain plugs. 100773-12 – Mount and tighten oil drain plugs with the magnet, O-rings, and oil screen.
  • Page 190 SERVICE WORK ON THE ENGINE – The oil must be added in two steps. Engine oil 3.60 l (3.8 qt.) Outside Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 215) Outside Engine oil (SAE temperature: 5W/40) ( p.

  • Page 191: 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 192 Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 215) 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 193 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 194: 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 195 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 196: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 219) – Oil the ignition/steering lock, tank lock, and seat lock. Universal oil spray ( p. 219) 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 197 CLEANING, CARE – Clean the chain. ( p. 108)

  • Page 198: 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 199: 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 200: Troubleshooting

    Recharge the battery. p. 158) – 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 201 Engine turns but does not start Coupling of fuel hose connection not Reconnect coupling of fuel hose connection. connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Fuel quality is insufficient Add suitable fuel. –...

  • Page 202: 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 stem diameter Intake 42 mm (1.65 in)

  • Page 203: 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 204 TECHNICAL DATA Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, pulse generator 6 Nm (4.4 lbf ft) Loctite ® 243™ – Bleeder screw, water pump cover 10 Nm (7.4 lbf ft) M6 – 10.9 Loctite ® 648™...
  • Page 205 TECHNICAL DATA Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite ® 243™ – Stud, chain shaft 8 Nm (5.9 lbf ft) Vacuum connection 2.5 Nm (1.84 lbf ft) Loctite ® 243™ Loctite ® 243™ Nozzle 100 M6x0.75 4 Nm (3 lbf ft) Oil nozzle M6x0.75 4 Nm (3 lbf ft)
  • Page 206 TECHNICAL DATA – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) – Spark plug M10x1 15 Nm (11.1 lbf ft) Cylinder head screw M11x1.5...

  • Page 207: Capacities

    TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Outside temperature: ≥ 0 °C Engine oil 3.60 l (3.8 qt.) Engine oil (SAE 10W/50) (≥ 32 °F) p. 215) Outside temperature: < 0 °C Engine oil (SAE 5W/40) (< 32 °F) p. 215) 23.3.2 Coolant Coolant...
  • Page 208 TECHNICAL DATA Brake system Front Double disc brake with radially mounted four-pot brake calipers, floating brake discs Rear Single disc brake with dual-piston brake caliper, floating brake disc Brake discs - diameter Front 320 mm (12.6 in) Rear 267 mm (10.51 in) Brake discs - wear limit Front 4 mm (0.16 in)

  • Page 209: Electrical System

    TECHNICAL DATA 23.5 Electrical system Battery YTZ14S Battery voltage: 12 V Nominal capacity: 11.2 Ah maintenance-free Fuse 58011109110 10 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 58011109140 40 A Low beam H11/socket PGJ19-2 12 V 55 W High beam H11/socket PGJ19-2 12 V...

  • Page 210: Tires

    Rear tires 90/90 V 21 M/C (54V) TL 150/70 ZR 18 M/C 70W TL Continental ContiTrailATTACK 2 Continental ContiTrailATTACK 2 Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.8N.25 Fork WP Suspension 4860 MXTA SPLIT...

  • Page 211: Shock Absorber

    TECHNICAL DATA Full payload 8 turns Spring length with preload spacer(s) 475 mm (18.7 in) Spring rate Medium (standard) 5.5 N/mm (31.4 lb/in) Fork length 915 mm (36.02 in) Air chamber length mm (3.74 +0.98 −15 −0.59 Fork oil per fork leg 720 ml (24.34 fl.

  • Page 212: Chassis Tightening Torques

    TECHNICAL DATA Sport 8 clicks Full payload 8 clicks Spring preload Comfort 4 turns Standard 4 turns Sport 4 turns Full payload 16 turns Spring rate Medium (standard) 170 N/mm (971 lb/in) Spring length 205 mm (8.07 in) Gas pressure 10 bar (145 psi) Riding sag 55 mm (2.17 in)
  • Page 213 TECHNICAL DATA – Screw, chain sliding guard 5 Nm (3.7 lbf ft) – Screw, combination switch, right 3.5 Nm (2.58 lbf ft) – Screw, cover part M5x12 3.5 Nm (2.58 lbf ft) – Screw, filler cap 3 Nm (2.2 lbf ft) Screw, foot brake lever stub 6 Nm (4.4 lbf ft) Loctite...
  • Page 214 TECHNICAL DATA – Screw, fuel pump 6 Nm (4.4 lbf ft) – Screw, fuel tank 10 Nm (7.4 lbf ft) – Screw, fuel tap 6 Nm (4.4 lbf ft) – Screw, lower rear part 6 Nm (4.4 lbf ft) Screw, magnetic holder on side stand 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 215 TECHNICAL DATA – Remaining chassis screws 45 Nm (33.2 lbf ft) Screw, front brake caliper 45 Nm (33.2 lbf ft) Loctite ® 243™ Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, side stand 35 Nm (25.8 lbf ft) Screw, side stand bracket 45 Nm (33.2 lbf ft)

  • Page 216: 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 possesses the correspond- ing properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 217 SUBSTANCES Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA ( p. 220) – SAE ( p. 220) (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.
  • Page 218 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 220) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper- ties. Hydraulic fluid (15) Standard/classification –...
  • Page 219 SUBSTANCES Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 220: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Recommended supplier Motorex ® – Moto Protect Fuel additive Recommended supplier Motorex...
  • Page 221 AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier...

  • Page 222: 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 223: Index

    INDEX INDEX Capacity ABS ........131 coolant .
  • Page 224 INDEX "General Info" ....... . 55 compensating tank, correcting ....180 "Heat Grip"...
  • Page 225 INDEX Fork ........Headlight mask with headlight compression damping, adjusting .
  • Page 226 INDEX Mask spoiler installing ........123 Rear hub rubber dampers removing .
  • Page 227 INDEX Shock absorber ....... . Switch compression damping ......100 on the left side of the handlebar .
  • Page 228 INDEX Troubleshooting ......198-199 Turn signal bulb changing ........171 Turn signal switch .
  • Page 229 *3213108en* 3213108en 10/2013 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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