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KTM 990 SupermotoR Owner's Manual

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OWNER'S MANUAL
2012
990 Supermoto R EU
990 Supermoto R FR
990 Supermoto R AUS/UK
Art. no. 3211794en

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Summary of Contents for KTM 990 SupermotoR

  • Page 1 OWNER'S MANUAL 2012 990 Supermoto R EU 990 Supermoto R FR 990 Supermoto R AUS/UK Art. no. 3211794en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as 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 Combination instrument - display........27 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Combination instrument - speedometer....... 28 IMPORTANT INFORMATION ........... 8 Setting kilometers or miles ..........28 VIEW OF VEHICLE..............12 Combination instrument - time .......... 29 View of vehicle, front left side (vehicle differs slightly from photo) ................
  • Page 6 TABLE OF CONTENTS RIDING INSTRUCTIONS ............45 Removing the seat ............70 Checks and maintenance measures when preparing for Mounting the seat ............71 use ................. 45 Mounting the helmet lock on the vehicle......71 Starting ................46 Reinstalling the fuel tank ..........72 Starting off ..............
  • Page 7 TABLE OF CONTENTS Removing the rear wheel ..........99 Adjusting the play in the throttle cable ......149 Ignition curve plug-in connector........149 Installing the rear wheel ..........101 Adjusting the ignition curve to the fuel quality....150 Checking rear hub shock absorbers ......
  • Page 8 TABLE OF CONTENTS TECHNICAL DATA - FORK........... 185 TECHNICAL DATA - SHOCK ABSORBER ......186 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ..188 SUBSTANCES..............191 AUXILIARY SUBSTANCES........... 195 STANDARDS..............197 INDEX ................198...

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! There, your motorcycle will be serviced opti- mally by specially trained experts using the specialist tools required.

  • Page 10: Important Information

    The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage result- ing from manipulation and/or other changes to the vehicle.
  • Page 11 Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 12 IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Secure the motorcycle against falling over or rolling away using straps or other suitable devices. Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons.
  • Page 13 IMPORTANT INFORMATION Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (vehicle differs slightly from photo) 101565-10...
  • Page 15 VIEW OF VEHICLE Combination instrument ( p. 24) Rear mirror Clutch lever ( p. 19) Seat Handrails ( p. 37) Level viewer, engine oil Shift lever ( p. 38) Engine number ( p. 17) Compression damping of the shock absorber ( p.

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

    VIEW OF VEHICLE View of vehicle, rear right side (vehicle differs slightly from photo) 101566-10...
  • Page 17 VIEW OF VEHICLE Seat lock ( p. 36) Light switch ( p. 20) Headlight flasher switch ( p. 21) Turn signal switch ( p. 21) Horn button ( p. 22) Filler cap Emergency OFF switch ( p. 22) Electric starter button ( p.

  • Page 18: Serial Numbers

    SERIAL NUMBERS Chassis number/type label Chassis number is embossed in the steering head at the right. 101093-10 Type label is applied to the right frame tube. 101094-10...

  • Page 19: Engine Number

    SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 101095-10 Key number The Code number key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 20: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 101567-10 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 101098-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. 101099-10...

  • Page 22: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. 101174-10 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is turned downwards. In this position, the low beam and tail light are switched on.

  • Page 23: Headlight Flasher Switch

    CONTROLS Headlight flasher switch The headlight flasher switch is fitted on the left side of the handlebar. Possible states • Headlight flasher switch in basic position Headlight flasher switch pressed – The headlight flasher switch (high beam) is oper- • ated in this position.

  • Page 24: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in basic position pressed – The horn is operated in this position. • Horn button 700550-12 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 25: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – The electric starter is actuated in this position. • Electric starter button 700552-11 Ignition/steering lock 5.10...

  • Page 26: Immobilizer

    The second black ignition key is activated when the vehicle is shipped. Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop, but they must be activated before use. Combination instrument 5.12 The combination instrument is installed in front of the handlebar.

  • Page 27: Combination Instrument - Function Buttons

    CONTROLS Combination instrument - function buttons 5.13 You can change the display mode with the MODE button Possible display modes are the distance traveled (ODO), trip master 1 (TRIP 1), trip mas- ter 2 (TRIP 2) and the ambient temperature. Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- tion (TRIP 2) to 0.0.

  • Page 28: Combination Instrument - Indicator Lamps

    CONTROLS Combination instrument - indicator lamps 5.15 The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up green –...

  • Page 29: Combination Instrument - Display

    CONTROLS Combination instrument - display 5.16 When you switch on the ignition, all display segments light up for one second as a function test. 400892-01 LEnGth Following the display function test, the LEnGth wheel circumference is shown for one sec- ond.

  • Page 30: Combination Instrument - Speedometer

    CONTROLS Combination instrument - speedometer 5.17 The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 Setting kilometers or miles 5.18 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country.

  • Page 31: Combination Instrument - Time

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.

  • Page 32: Combination Instrument - Odo Display

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –...

  • Page 33: Combination Instrument - Setting/Resetting Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 400840-01 Combination instrument - setting/resetting TRIP 2 5.23...

  • Page 34: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.24 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 400842-01 Combination instrument - ambient temperature display 5.25...

  • Page 35: Setting The Temperature Units

    CONTROLS Setting the temperature units 5.26 Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ambient temperature is active. – Keep the MODE button pressed until the display mode changes from °C to °F or from °F to °C.

  • Page 36: Combination Instrument - Coolant Temperature Indicator

    CONTROLS Combination instrument - coolant temperature indicator 5.28 The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up.

  • Page 37: Closing The Filler Cap

    CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Lift the cover of the filler cap and insert the ignition key. Note Danger of damage Ignition key breakage.

  • Page 38: Seat Lock

    CONTROLS Seat lock 5.31 Seat lock is located at the rear under the tail light. It can be locked with the ignition key. 101104-10 Tool set 5.32 The tool set is located in the storage compartment under the seat. 101571-10...

  • Page 39: Handrails

    CONTROLS Handrails 5.33 The handrails are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the handrails during the trip. 101570-10 Helmet lock 5.34 Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle.

  • Page 40: Passenger Footrests

    CONTROLS Passenger footrests 5.35 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. • 101573-01 Shift lever 5.36 Shift lever is mounted on the left side of the engine.

  • Page 41: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gear. 101109-10 Foot brake lever 5.37 Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. 101110-10...

  • Page 42: Side Stand

    CONTROLS Side stand 5.38 The side stand is located on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –...

  • Page 43: 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 44: Running In The Engine

    PREPARING FOR USE – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully.
  • Page 45 PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. – Mount and secure suitcase and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. –...
  • Page 46 PREPARING FOR USE – If you are carrying baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri- bution between the front and rear wheels. – Do not exceed the maximum permissible total weight and the axle loads. Guideline Maximum permissible total weight 400 kg (882 lb.)

  • Page 47: Riding Instructions

    RIDING INSTRUCTIONS 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. – Check the engine oil level.

  • Page 48: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 49 Take the weight off the side stand and swing it upwards with your foot as far as it will Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous.

  • Page 50: Starting Off

    RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 51 RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
  • Page 52 Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 53: Braking

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 54 RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. Warning Danger of accidents Greater stopping distance due to ABS.

  • Page 55: Stopping, Parking

    RIDING INSTRUCTIONS – On long downhill stretches, use the braking effect of the engine. Do this by changing down two gears, but do not race the engine. You will require less braking force and the brakes will not overheat. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons.

  • Page 56: Refueling

    RIDING INSTRUCTIONS – Apply the brakes. – Shift the transmission to neutral. – Switch off the ignition by turning the ignition key to the OFF position. Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery is soon discharged.
  • Page 57 – 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 58: Service Schedule

    Check that the electrical equipment is functioning properly. • • • • • • • • Read out the trouble code memory using the KTM diagnostics tool. • • • Check the measured service values with the KTM diagnostics tool. • • • •...
  • Page 59 Change the air filter. Clean the air filter box. • • • Check the fuel pressure. Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics • • • tool. Check the CO adjustment with the KTM diagnostics tool.
  • Page 60 • • • • • • Read out the fault memory after a test ride using the KTM diagnostics tool. • • • • Make the service entries in the KTM DEALER.NET and service record. K10N: Once after 1,000 km (621.4 mi)

  • Page 61: Tuning The Chassis

    TUNING THE CHASSIS Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to your rid- ing style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .

  • Page 62: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping 101574-10...

  • Page 63: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping 101116-10...
  • Page 64 TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of turns according to the fork type. Guideline Spring preload - Preload Adjuster 101117-10...

  • Page 65: 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 can be seen during the slow to normal compression of the shock absorber.

  • Page 66: 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 can be seen during the fast compression of the shock absorber.

  • Page 67: 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 68: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 101575-10 Full payload 10 clicks...
  • Page 69 TUNING THE CHASSIS Preliminary work – Take the weight off the rear wheel and swingarm. Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are fully relieved of weight. Main work – Release retaining ring –...

  • Page 70: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the front wheel stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Preliminary work – Raise the motorcycle with the rear wheel stand.

  • Page 71: Raising The Motorcycle With The Rear Wheel Stand

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the rear wheel stand 10.3 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the lifting bushings on the swingarm. –...

  • Page 72: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS Bleeding the fork legs 10.5 Preliminary work – Lean the motorcycle on the side stand. Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten the bleeder screws. Info Carry out this operation on both fork legs.

  • Page 73: Mounting The Seat

    SERVICE WORK ON THE CHASSIS Mounting the seat 10.7 – Position front recesses of the seat on the oval head screws of the fuel tank, lower the rear and simultaneously push it forward. Both lugs must hook into the frame and locking bolt must be inserted into the lock housing.

  • Page 74: Reinstalling The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Position the steel cable from the tool set with one loop on hook Steel cable (60012015000) – Guide the steel cable through the helmet opening. – Attach the free loop of the steel cable to the hook as well. –...

  • Page 75: Positioning The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screw on both sides. Info The fuel hoses do not need to be disconnected. 101164-10 – Remove screw – Carefully push the fuel tank back. 101165-10 Positioning the fuel tank 10.10 Main work –...
  • Page 76 SERVICE WORK ON THE CHASSIS – Mount and tighten screw with the collar bushing. Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 101165-11 – Install and tighten screw with the bearing sleeve and rubber bushing on both sides. Guideline Remaining chassis screws 25 Nm (18.4 lbf ft)

  • Page 77: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS Subsequent work – Mount the seat. ( p. 71) Checking the chain for dirt 10.11 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p.

  • Page 78: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.

  • Page 79: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Shift the transmission to neutral. – In the area after the chain sliding guard, press the chain upward toward the link fork and measure chain tension Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 80 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 7 mm (0.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjuster are in the same position in relation to reference marks .

  • Page 81: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Checking the chain, rear sprocket, engine sprocket and chain guide 10.15 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Replace the rear sprocket or engine sprocket. Info The rear sprocket, engine sprocket and chain should always be changed together.
  • Page 82 SERVICE WORK ON THE CHASSIS – Shift the transmission to neutral. – Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 83 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If there is no gap between the chain and the upper edge of the screw: – Change the chain sliding guard. – Check the chain sliding guard for tightness. »...

  • Page 84: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS Adjusting the basic position of the clutch lever 10.16 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. The range of adjustment is limited.
  • Page 85 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »...

  • Page 86: Brakes

    – The ABS will only function correctly if the spare parts used in the brake system and the tires have been approved and/or recommended by KTM. – Maintenance work and repairs must be carried out professionally. (Your autho- rized KTM workshop will be glad to help.)

  • Page 87: Adjusting The Basic Position Of The Hand Brake Lever

    Do not make any adjustments while riding! 101124-10 Checking the front brake discs 11.3 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 88: Checking The Front 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.)

  • Page 89: 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 90: Checking The Front Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. Checking the front brake linings 11.6 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 91: Checking The Free Travel Of The Foot Brake Lever

    BRAKES Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable. Check the brake linings regularly. –...

  • Page 92: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKES – Move the foot brake lever back and forth between the end stop and the contact to the piston rod and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The piston rod should not move. »...

  • Page 93: Checking The Rear Brake Disc

    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 94: Adding Rear Brake Fluid

    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.) – Stand the vehicle upright.
  • Page 95 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 96: Checking The Rear Brake Linings

    11.12 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly...
  • Page 97 BRAKES – 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 98: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 Preliminary work – Raise the motorcycle with the rear wheel stand. ( p. 69) – Raise the motorcycle with the front wheel stand. ( p. 68) Main work – Take the speed sensor cable out of the clamp. –...

  • Page 99: Installing The Front Wheel

    WHEELS, TIRES Installing the front wheel 12.2 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 100 WHEELS, TIRES – Slide the sleeve onto the wheel speed sensor and push them into the hole together. Mount and tighten screw Guideline Screw, wheel speed sensor 6 Nm Loctite ® 243™ (4.4 lbf ft) – Fasten the speed sensor cable in the bracket. –...

  • Page 101: Removing The Rear Wheel

    WHEELS, TIRES – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 101592-10 Removing the rear wheel 12.3 Preliminary work – Raise the motorcycle with the rear wheel stand.
  • Page 102 WHEELS, TIRES Main work – Remove screw and pull wheel speed sensor out of the hole. – Remove nut . Remove chain adjuster – Pull out wheel spindle to the point where the chain adjuster is no longer in contact with the adjusting screw.

  • Page 103: Installing The Rear Wheel

    WHEELS, TIRES – Take the rear wheel carefully out of the swingarm without damaging the rim and/or brake disc. Info Do not operate the foot brake when the rear wheel is removed. Installing the rear wheel 12.4 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...
  • Page 104 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Remove bushing . Clean and grease the mating surfaces of the bushing and the shaft seal ring.
  • Page 105 WHEELS, TIRES – Engage the counter bearing of the brake caliper support and swingarm. Carefully lift the rear wheel into the swingarm and engage the brake disc. Lay the chain on the rear sprocket and mount the wheel spindle. – Mount chain adjuster and nut Info...

  • Page 106: Checking Rear Hub Shock Absorbers

    WHEELS, TIRES Checking rear hub shock absorbers 12.5 Info The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out dur- ing operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged. Preliminary work –...

  • Page 107: 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 108: 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 109 WHEELS, TIRES – Remove the dust cap. – Check the tire air pressure when the tires are cold. Tire air pressure, solo Front 2.4 bar (35 psi) Rear 2.4 bar (35 psi) Tire air pressure with passenger/full payload Front 2.4 bar (35 psi) 400695-01 Rear 2.6 bar (38 psi)

  • Page 110: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 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 111 ELECTRICAL SYSTEM Main work – Disconnect negative (minus) cable of the battery. 101595-10 – Remove positive terminal cover – Disconnect the positive (plus) cable of the battery. – Detach rubber band – Pull the battery up and out of the battery rack. 101596-10...

  • Page 112: Installing The Battery

    ELECTRICAL SYSTEM Installing the battery 13.2 Main work – Position the battery in the battery rack. Info The terminals of the battery must face in the direction of travel. – Attach rubber band – Position washer and detach positive cable of the battery.

  • Page 113: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 114 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 115: Changing The Main Fuse

    ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid Charge the battery to no more than 10% of the capacity specified on battery...
  • Page 116 ELECTRICAL SYSTEM Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. Preliminary work – Switch off all power consumers and the engine. – Remove the seat. ( p. 70) Main work –...

  • Page 117: Changing The Abs Fuses

    ELECTRICAL SYSTEM Changing the ABS fuses 13.5 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 Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box.

  • Page 118: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse – Insert the new fuse. Fuse (58011109130) – Check that the ABS warning lamp still lights up. – Mount the protection cap. 101601-10 Follow-up work –...
  • Page 119 ELECTRICAL SYSTEM Main work – Open fuse box cover – Check the fuses. Info A faulty fuse can be identified by the burned-out fuse wire – Remove the faulty fuse. Guideline 101602-10 Fuse 1 - 10 A - ignition, fuel pump, hazard warning flasher Fuse 2 - 15 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 3 - 10 A - horn, brake light, turn signal Fuse 4 - 10 A - radiator fan...

  • Page 120: Changing The Headlight Bulb

    ELECTRICAL SYSTEM Insert a spare fuse so that it is available if needed. – Close the fuse box cover. Follow-up work – Mount the seat. ( p. 71) Changing the headlight bulb 13.7 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 121 ELECTRICAL SYSTEM – Cover the fender with a cloth. – Swing the headlight mask forward and pull it upward out of holding lugs 101146-10 – Disconnect connector – Remove rubber cap 700592-10 – Push off retaining clamp on both sides, squeeze and fold down. –...
  • Page 122 ELECTRICAL SYSTEM – Position the retaining clamp. – Mount rubber cap – Plug in connector 700592-10 – Position holes onto holding lugs 101146-11...

  • Page 123: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Position the headlight mask. Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Check that the lighting is functioning properly. 101145-10 Changing the parking light bulb 13.8 Note Damage to reflector Reduced luminance. –...
  • Page 124 ELECTRICAL SYSTEM – Cover the fender with a cloth. – Swing the headlight mask forward and pull it upward out of holding lugs 101146-10 – Pull the parking light carefully out of the holder. – Remove the bulb. – Position a new light bulb in the holder. Parking light (W5W/socket W2.1x9.5d) ( p.

  • Page 125: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Position holes onto holding lugs 101146-12 – Position the headlight mask. Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Check that the lighting is functioning properly. 101145-10 Changing the turn signal bulb 13.9 Note Damage to reflector Reduced luminance.

  • Page 126: Changing The Brake Light Bulb

    ELECTRICAL SYSTEM – Remove the screw on the rear of the turn signal housing. – Carefully remove diffuser – Press bulb carefully into the socket, turn it counterclockwise by about 30°, and pull it out of the socket. – Press the new bulb carefully into the socket and turn it clockwise until it stops. Turn signal (RY10W/socket BAU15s) ( p.
  • Page 127 ELECTRICAL SYSTEM Main work – Remove screws – Remove the grab handles. 101603-10 – Remove screws – Remove screws on the left and right rear side part. – Remove the rear side part. 101604-10...
  • Page 128 ELECTRICAL SYSTEM – Remove screws – Remove the top part. 101605-10 – Turn bulb socket counterclockwise all the way and take it out of the tail light. – Push the bulb carefully into the socket, turn it counterclockwise and pull it out of the socket.
  • Page 129 ELECTRICAL SYSTEM – Position the rear top part. – Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 101605-10 – Position the rear side parts. – Mount and tighten screws Guideline Remaining chassis screws 5 Nm (3.7 lbf ft) Remaining frame bolts EJOT PT K50x12 1.2 Nm...

  • Page 130: Changing The Tail Light Bulbs

    ELECTRICAL SYSTEM – Position the grab handles. – Mount and tighten screws Guideline Screw, handrail 20 Nm (14.8 lbf ft) 101603-10 Follow-up work – Mount the seat. ( p. 71) Changing the tail light bulbs 13.11 Note Damage to reflector Reduced luminance. –...
  • Page 131 ELECTRICAL SYSTEM Main work – Remove screws – Remove the grab handles. 101603-10 – Remove screws – Remove screws on the left and right rear side part. – Remove the rear side part. 101604-10...
  • Page 132 ELECTRICAL SYSTEM – Remove screws – Remove the top part. 101605-10 – Pull bulb holders carefully out of the bracket. – Remove the bulb. – Position a new light bulb in the holder. Tail light (WR5W/socket W2.1x9.5d) ( p. 184) –...
  • Page 133 ELECTRICAL SYSTEM – Position the rear top part. – Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 101605-10 – Position the rear side parts. – Mount and tighten screws Guideline Remaining chassis screws 5 Nm (3.7 lbf ft) Remaining frame bolts EJOT PT K50x12 1.2 Nm...

  • Page 134: Changing The License Plate Lamp

    ELECTRICAL SYSTEM – Position the grab handles. – Mount and tighten screws Guideline Screw, handrail 20 Nm (14.8 lbf ft) 101603-10 Follow-up work – Mount the seat. ( p. 71) Changing the license plate lamp 13.12 Main work – Remove screws –...
  • Page 135 ELECTRICAL SYSTEM – Pull holder carefully out of the bracket. – Remove the bulb. – Position a new light bulb in the holder. License plate lamp (W5W/socket W2.1x9.5d) ( p. 184) – Carefully position the holder with the bulb into the bracket. 101608-10 –...

  • Page 136: Checking The Headlight Setting

    ELECTRICAL SYSTEM Checking the headlight setting 13.13 – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the level of the center of the headlight. 0 0 A – Make another mark at a distance of under the first mark.

  • Page 137: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM – Turn screw to adjust the headlight range. Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking the headlight adjustment). Info Turn clockwise to increase the headlight range;...
  • Page 138 ELECTRICAL SYSTEM Loss of a black ignition key (second black ignition key available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Press the emergency OFF switch into the position 401184-10 – Insert the orange programming key in the ignition lock.
  • Page 139 ELECTRICAL SYSTEM Immobilizer indicator lamp lights up, switches off briefly and flashes; the number of flashes equals the number of functional black ignition keys includ- ing the orange programming key. In this case, twice. – Switch off the ignition by turning the orange programming key to the OFF position –...
  • Page 140 ELECTRICAL SYSTEM – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. All black ignition keys are deactivated. – Order a new black ignition key according to the key number on the KEYCODECARD and activate it.
  • Page 141 ELECTRICAL SYSTEM The immobilizer indicator lamp lights up, switches off briefly and flashes; the number of flashes equals the number of functional black ignition keys including the orange programming key. – Switch off the ignition by turning the orange programming key to the OFF position –...

  • Page 142: Cooling System

    COOLING SYSTEM Cooling system 14.1 The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radia- tor cap. This permits the specified coolant temperature without causing any malfunctions. 125 °C (257 °F) 101155-10 Cooling takes place by means of the air stream and a radiator fan, which is controlled by a...
  • Page 143 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 144 COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 191) » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! – Fill/bleed the cooling system. p.

  • Page 145: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM Checking the coolant level in the compensating tank 14.3 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 146: Draining The Coolant

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 191) – Mount the cap of the compensating tank. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! –...

  • Page 147: Filling/Bleeding The Cooling System

    COOLING SYSTEM Main work – Place a suitable container under the radiator. – Remove radiator cap – Remove screw – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 101159-10 –...
  • Page 148 COOLING SYSTEM Preliminary work – Remove the seat. ( p. 70) – Reset the fuel tank. ( p. 72) Main work – Ensure that the drain plug on the radiator and the water pump cover are tightened. – Remove bleeder screw 101161-10 –...
  • Page 149 COOLING SYSTEM – Remove the radiator cap and pour in coolant until it emerges without bubbles at the vent hole, and then immediately mount and tighten the bleeder screw Alternative 1 Coolant ( p. 191) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 150: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 151: Adjusting The Play In The Throttle Cable

    Adjusting the play in the throttle cable 15.2 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the basic position. – Push back sleeve – Loosen lock nut –...

  • Page 152: Adjusting The Ignition Curve To The Fuel Quality

    TUNING THE ENGINE Adjusting the ignition curve to the fuel quality 15.4 Preliminary work – Switch off the ignition by turning the ignition key to the OFF position. – Remove the seat. ( p. 70) To activate the ignition curve for low octane fuel: Note Engine failure Low-quality fuel damages the engine.

  • Page 153: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE Checking the basic position of the shift lever 15.5 – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
  • Page 154 TUNING THE ENGINE – 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 155: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Preliminary work Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 156: Changing The Engine Oil And Filter, Cleaning The Oil Screens X

    SERVICE WORK ON THE ENGINE Changing the engine oil and filter, cleaning the oil screens 16.2 – Drain the engine oil and filter, clean the oil screens. p. 154) – Fill up with engine oil. p. 159) B00119-01 Draining the engine oil and filter, cleaning the oil screens 16.3 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
  • Page 157 SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring. – Fully drain the engine oil out of the engine. 700611-10 – Remove screws and cover 700610-10 –...
  • Page 158 SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove oil drain plug – Fully drain the engine oil out of the oil tank. – Remove screws and move oil line to one side. 101171-10 –...
  • Page 159 SERVICE WORK ON THE ENGINE – Insert oil filter – Lubricate the O-ring of the oil filter cover. – Mount the oil filter cover . Mount and tighten the screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) – Position the oil line.
  • Page 160 SERVICE WORK ON THE ENGINE – Position oil line . Mount and tighten screws Guideline Remaining engine screws 10 Nm (7.4 lbf ft) – Mount oil drain plug with the magnet and new seal and tighten. Guideline Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft)

  • Page 161: Filling Up With Engine Oil

    SERVICE WORK ON THE ENGINE Filling up with engine oil 16.4 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – The oil must be added in two steps. Engine oil 3.0 l (3.2 qt.) External Engine oil temperature:...

  • Page 162: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the plug. – Add engine oil to the top marking – Mount the plug. Adding engine oil 16.5 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. The engine oil level must be corrected when the engine is warm.

  • Page 163: Cleaning, Care

    CLEANING, CARE Cleaning motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 164 CLEANING, CARE – After the motorcycle has been thoroughly cleaned with a gentle jet of water, it should be dried with compressed air and a cloth. Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. –...

  • Page 165: Checks And Maintenance Measures For Winter Operation

    CLEANING, CARE Checks and maintenance measures for winter operation 17.2 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after use. Warm water would enhance the corrosive effects of salt. –...

  • Page 166: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 69) – Raise the motorcycle with the front wheel stand. (...

  • Page 167: Preparing For Use After Storage

    STORAGE – Cover the motorcycle with a tarp or cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

  • Page 168: Troubleshooting

    Reconnect coupling of fuel hose connection. connected – Socket connector of wiring harness Clean the socket connector and treat it with con- oxidized tact spray. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 169 Engine has too little power Air filter very dirty Change the air filter. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine overheats Too little coolant in cooling system Check the cooling system for leaks.
  • Page 170 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 153) – Engine oil too thin (low viscosity) Change the engine oil and filter, clean the oil screens. p. 154) –...

  • Page 171: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Blink code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition ICU antenna malfunction Blink code of immobilizer indica-...
  • Page 172 IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition ICU is not activated Blink code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica-...

  • Page 173: Engine Control Blink Code

    ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Circuit ignition pulse generator - circuit fault Blink code of FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle valve sensor circuit A - input signal too low Throttle valve sensor circuit A - input signal too high...
  • Page 174 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 12 FI warning lamp (MIL) flashes 1x long, 2x short Error level condition Coolant temperature sensor - input signal too low Coolant temperature sensor - input signal too high Blink code of FI warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short...
  • Page 175 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 18 FI warning lamp (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Blink code of FI warning lamp (MIL) 24 FI warning lamp (MIL) flashes 2x long, 4x short Error level condition Power supply - circuit fault...
  • Page 176 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code of FI warning lamp (MIL) 38 FI warning lamp (MIL) flashes 3x long, 8x short Error level condition Ignition coil 1, cylinder 2 - circuit fault Blink code of FI warning...
  • Page 177 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 49 FI warning lamp (MIL) flashes 4x long, 9x short Error level condition Motor drive circuit A - circuit fault Blink code of FI warning lamp (MIL) 50 FI warning lamp (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Blink code of FI warning...
  • Page 178 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 81 FI warning lamp (MIL) flashes 8x long, 1x short Error level condition Immobilizer control unit - circuit fault Blink code of FI warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition Malfunction in CAN bus communication...

  • Page 179: Technical Data - Engine

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

  • Page 180: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 5th gear 24:27 6th gear 27:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug NGK LKAR8BI9 Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump Idle speed...

  • Page 181: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) ® Screw, oil spray tube 6 Nm (4.4 lbf ft) Loctite 243™ – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 182 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, valve cover 10 Nm (7.4 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) ® Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite 243™ ® Vacuum connection 2.5 Nm (1.84 lbf ft) Loctite 243™...
  • Page 183 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 60° – Spark plug M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –...

  • Page 184: Technical Data - Chassis

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

  • Page 185: Lighting Equipment

    TECHNICAL DATA - CHASSIS Rear 2.6 bar (38 psi) Secondary drive ratio 17:41 Chain 5/8 x 5/16” X‑ring Steering head angle 65.6° Wheelbase 1,505 mm (59.25 ±15 ±0.59 Seat height, unloaded 875 mm (34.45 in) Ground clearance, unloaded 195 mm (7.68 in) Weight without fuel, approx.

  • Page 186: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Turn signal RY10W/socket BAU15s 12 V 10 W Tail light WR5W/socket W2.1x9.5d 12 V Brake light PR21W/socket BAW15s 12 V 21 W License plate lamp W5W/socket W2.1x9.5d 12 V Capacity - fuel 24.2 Total fuel tank capacity, approx. 15 l (4 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 187: Technical Data - Fork

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

  • Page 188: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7L.21 Shock absorber WP Suspension 4618 BAVP DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn...
  • Page 189 TECHNICAL DATA - SHOCK ABSORBER Gas pressure 10 bar (145 psi) Static sag 20 mm (0.79 in) Fitted length 372 mm (14.65 in) Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 193)

  • Page 190: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining frame bolts EJOT Delta PT 50x12 1.2 Nm (0.89 lbf ft) – Remaining frame bolts EJOT PT K50x12 T20 1.2 Nm (0.89 lbf ft) – Remaining frame bolts EJOT PT K50x18 T20 2 Nm (1.5 lbf ft) –...
  • Page 191 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, splash protector 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, spoiler 3.3 Nm (2.43 lbf ft) ® Screw, wheel speed sensor 6 Nm (4.4 lbf ft) Loctite 243™ – Nut, manifold on cylinder head Tightening sequence: Tighten the nuts uniformly.
  • Page 192 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw connection, engine mounting 45 Nm (33.2 lbf ft) bracket – Screw, handlebar support 20 Nm (14.8 lbf ft) ® Screw, side stand 35 Nm (25.8 lbf ft) Loctite 243™ ® Screw, side stand bracket 45 Nm (33.2 lbf ft) Loctite 243™...

  • Page 193: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 194 SAE ( p. 197) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Fully synthetic engine oil Supplier ® Motorex –...
  • Page 195 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
  • Page 196 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) 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.

  • Page 197: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 198 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Bike Grease 2000 Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Universal oil spray Guideline – ®...

  • Page 199: 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 200: Index

    INDEX Brake light bulb INDEX changing ........124 ABS .
  • Page 201 INDEX display, ambient temperature ..... 32 Engine number ........17 function buttons .
  • Page 202 INDEX removing ........96 plug-in connector ......149 Fuel tank Ignition key positioning...
  • Page 203 INDEX Oil screens Riding ........cleaning .
  • Page 204 INDEX Tachometer ........25 Vehicle Tail lamp bulbs loading .
  • Page 205 *3211794en* 3211794en 11/2011 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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