KTM 990 Adventure Baja Owner's Manual
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KTM 990 Adventure Baja Owner's Manual

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2013
OWNER'S MANUAL
990 Adventure Baja
Art. no. 3211908en

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  • Page 1 2013 OWNER'S MANUAL 990 Adventure Baja Art. no. 3211908en...
  • 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 SERIAL NUMBERS ............28 TABLE OF CONTENTS MEANS OF REPRESENTATION ........8 Chassis number ..........28 Symbols used ............8 Type label ............28 Formats used............8 Key number............29 SAFETY ADVICE.............. 9 Engine number ..........30 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS 6.12.10 ODO display ..........43 Running in the engine ........59 6.12.11 Setting/resetting display TRIP 1 ...... 43 Loading the vehicle ..........60 6.12.12 Setting/resetting display TRIP 2 ...... 44 RIDING INSTRUCTIONS..........62 6.12.13 TRIP F display..........45 Checks and maintenance measures when preparing for use..........
  • Page 7 TABLE OF CONTENTS 11.2 Raising the vehicle off of the center stand .... 87 11.28 Installing the underride guard ...... 110 11.3 Bleeding the fork legs......... 87 12 BRAKE SYSTEM ............111 11.4 Cleaning the dust boots of the fork legs....88 12.1 Checking the free travel of the hand brake lever ...............
  • Page 8 TABLE OF CONTENTS 14.6 Removing the headlight mask with the 17.4 Removing the oil filter ......... 172 headlight............140 17.5 Installing the oil filter ........173 14.7 Installing the headlight mask with the 17.6 Filling up with engine oil ......173 headlight............
  • Page 9 TABLE OF CONTENTS 32 STANDARDS .............. 218 INDEX ................219...

  • 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 B01338-10...
  • Page 15 SAFETY ADVICE Information on starting up Information on tires USA type label Information on emission control Information on suspension tuning Information on refueling Information on chain tension Information on noise emission Canada type label Information on starting up 700210-01...
  • Page 16 SAFETY ADVICE B01344-01 Information on tires B01340-01 USA type label...
  • Page 17 SAFETY ADVICE B01339-01 Information on emission control B01341-01 Information on suspension tuning...
  • Page 18 SAFETY ADVICE Information on refueling 400630-01 400628-01 Information on chain tension...

  • Page 19: Reporting Safety Defects

    If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM...

  • Page 20: Noise Emission Warranty

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

  • Page 21: Tampering Warning

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

  • Page 22: Protective Clothing

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

  • Page 23: Environment

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

  • Page 24: Important Notes

    Warranty The work 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 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 (example) B01345-10...
  • Page 27 VIEW OF VEHICLE Indicator lamps ( p. 39) Function buttons ( p. 38) Clutch lever ( p. 32) Tool set ( p. 53) Seat lock ( p. 53) Luggage rack plate ( p. 54) Handrails ( p. 54) Fork compression adjustment Fuel taps ( p.

  • Page 28: View Of Vehicle, Rear Right Side (Example)

    VIEW OF VEHICLE View of vehicle, rear right side (example) B01346-10...
  • Page 29 VIEW OF VEHICLE Fork rebound adjustment Light switch ( p. 34) Turn signal switch ( p. 35) Horn button ( p. 33) Headlight flasher switch ( p. 34) Hazard warning flasher switch/hazard warning flasher ( p. 47) Ignition/steering lock ( p.

  • Page 30: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. The chassis number is also found on the type label. 100542-10 Type label The USA type label is located on the right frame tube in the area of the oil tank. B00891-10...

  • Page 31: Key Number

    SERIAL NUMBERS The Canada type label is located on the right frame tube under the seat. B01348-10 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 left side of the engine under the engine sprocket. 100544-10 Fork part number The fork part number is stamped on the inner side of the fork stub. 100545-10...

  • 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. 100546-10...

  • 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. 100505-10 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. 100506-10...

  • Page 35: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. B01347-10 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. •...

  • Page 36: Light Switch

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

  • Page 37: Turn Signal Switch

    CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use. Turn signal, right, on –...

  • Page 38: 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 is pressed – The electric starter is actuated in this position. • Electric starter button 100548-10 6.10 Ignition/steering lock...

  • Page 39: Immobilizer

    The second black ignition key is activated when the vehicle is shipped. Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop, but they need to be activated for use. 6.12 Combination instrument 6.12.1...

  • Page 40: Function Buttons

    CONTROLS 6.12.2 Function buttons 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 41: Indicator Lamps

    CONTROLS 6.12.4 Indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idle speed indicator lamp lights up green – The transmission is switched to idle.

  • Page 42: Display

    CONTROLS 6.12.5 Display 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 wheel circumference LEnGth is shown for one sec- ond. Info 2205 mm equals the circumference of the 21" front wheel with a series production tire.

  • Page 43: Speed Display

    CONTROLS 6.12.6 Speed display The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 6.12.7 Setting kilometers or miles Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is standing.

  • Page 44: Time

    CONTROLS – Switch on the ignition by turning the black ignition key to the position ON – 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 45: 6.12.10 Odo Display

    CONTROLS – Switch on the ignition by turning the black ignition key to the position ON – 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 46: Setting/Resetting Display Trip 2

    CONTROLS – Switch on the ignition by turning the black ignition key to the position ON – 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 6.12.12 Setting/resetting display TRIP 2 Info...

  • Page 47: 6.12.13 Trip F Display

    CONTROLS 6.12.13 TRIP F display 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 6.12.14 Ambient temperature indicator The ambient temperature...

  • Page 48: 6.12.16 Warning Of Icy Roads

    CONTROLS – Switch on the ignition by turning the black ignition key to the position ON – 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 49: 6.12.17 Coolant Temperature Indicator

    CONTROLS 6.12.17 Coolant temperature indicator 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. Possible states Engine cold –...

  • Page 50: Socket For Electrical Accessories

    CONTROLS 6.14 Socket for electrical accessories The socket for electrical accessories is located to the left of the combination instrument. It is connected to the battery without an additional switch. Socket for electrical accessories Voltage 12 V Maximum current con- 10 A sumption B00116-10...
  • Page 51 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 in the lock. Note Danger of damage Ignition key breakage.

  • Page 52: Closing The Filler Caps

    CONTROLS 6.16 Closing the filler caps Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – When closing the filler cap, ensure that it is closed correctly. Change cloth- ing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.

  • Page 53: Locking The Storage Compartment

    CONTROLS 6.18 Locking the storage compartment – Insert the ignition key into the seat lock. – Turn the ignition key to position – Remove the ignition key. B01352-10 6.19 Opening the storage compartment – Unlock the storage compartment. ( p. 50) –...

  • Page 54: Closing The Storage Compartment

    CONTROLS 6.20 Closing the storage compartment – Push down on the rear of the cover until it audibly engages. Info The storage compartment can be opened again as long as it has not been locked using the seat lock. – Lock the storage compartment.

  • Page 55: Seat Lock

    CONTROLS 6.22 Seat lock The seat lock is located in the left side cover below the seat. The seat lock unlocks the seat and locks and unlocks the storage compartment. Possible states • Storage compartment locked • Storage compartment unlocked •...

  • Page 56: Handrails

    CONTROLS 6.24 Handrails The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the trip. B01356-10 6.25 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.

  • Page 57: Passenger Footrests

    CONTROLS 6.26 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. • B01357-01 6.27 Shift lever Shift lever is mounted on the left side of the engine.

  • Page 58: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100527-10 6.28 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. 100525-10...

  • Page 59: Side Stand

    CONTROLS 6.29 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. Side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –...

  • Page 60: 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 61: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 62: Loading The Vehicle

    PREPARING FOR USE Guideline Maximum engine speed During the first: 1,000 km (621.4 mi) 6,500 rpm After the first: 1,000 km (621.4 mi) 9,500 rpm – Avoid full-throttle operation! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.
  • Page 63 PREPARING FOR USE Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed properly at regular intervals.

  • Page 64: 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 65: Starting

    RIDING INSTRUCTIONS 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 66 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position – Switch on the ignition by turning the black ignition key to the position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 67: 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 68 RIDING INSTRUCTIONS Warning Danger of accidents Danger of accidents caused by dangerous driving. – Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on. 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.
  • Page 69 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 70: 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 71: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.
  • Page 72 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. Note Danger of damage The parked vehicle may roll away or fall over.

  • Page 73: Transport

    RIDING INSTRUCTIONS – Switch off the ignition by turning the black ignition key to the position OFF 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 74: Refueling

    Material damage Premature clogging of the fuel filter. – 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.)
  • Page 75 RIDING INSTRUCTIONS – Only refuel with clean fuel that meets the specified standards. 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. –...
  • Page 76 RIDING INSTRUCTIONS – Adjust the ignition curve to the fuel quality. ( p. 166) – Press the SET button for two seconds. The fuel level warning lamp switches off. TRIP F is set to 0.0 and the previous display mode appears. Info If you do not press the SET button , the reset takes place automatically after...

  • Page 77: 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 78 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 79 • • • • • • Read out the error memory after the test ride using the KTM diagnostics tool. • • • • Make the necessary service entries in the KTM DEALER.NET and service record. K10N: Once after 1,000 km (621.4 mi)

  • Page 80: Tuning The Chassis

    TUNING THE CHASSIS 10.1 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 81: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. – Mount protection covers 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior.

  • Page 82: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS Guideline Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.4 Adjusting the spring preload of the fork – Turn adjusting screws counterclockwise all the way.

  • Page 83: 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 84: 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 85: 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 86: 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 87 TUNING THE CHASSIS – 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 - Preload Adjuster Comfort 4 turns Standard 4 turns Sport 8 turns...

  • Page 88: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the vehicle using 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 89: Raising The Vehicle Off Of The Center Stand

    SERVICE WORK ON THE CHASSIS 11.2 Raising the vehicle off of 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. – Unlock the steering and move the vehicle forward with both hands on the handlebar. –...

  • Page 90: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. Info Carry out this operation on both fork legs. 100536-10 11.4 Cleaning the dust boots of the fork legs Preparatory work –...

  • Page 91: 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 92: Removing The Front Side Cover

    SERVICE WORK ON THE CHASSIS – Move the handlebar to and fro over the entire steering range. It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions. » If detent positions are detected: –...

  • Page 93: Removing The Radiator Guard

    SERVICE WORK ON THE CHASSIS – Position side cover at the fuel tank on the bottom and hold it at an angle. – Attach the overflow hose of the fuel tank to the connector. – Connect the plug-in connectors of the turn signal cables and swing the side cover up toward the vehicle.

  • Page 94: Installing The Radiator Guard

    SERVICE WORK ON THE CHASSIS – Pull nuts off of the radiator. Insert the screws into the holes of the radiator guard and mount the nuts. This ensures that all required parts are available when needed. 100642-10 11.9 Installing the radiator guard –...

  • Page 95: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11.10 Removing the seat – Insert the ignition key into the seat lock. – Turn the ignition key to position – Lift up the seat at the rear, pull it back and remove from above. –...

  • Page 96: Removing The Crash Bar

    SERVICE WORK ON THE CHASSIS 11.12 Removing the crash bar Info The operations are the same for the left and right sides. Preparatory work – Raise the vehicle using the center stand. ( p. 86) Main work – Remove screw 101563-10 –...

  • Page 97: Installing The Crash Bar

    SERVICE WORK ON THE CHASSIS 11.13 Installing the crash bar Info The operations are the same for the left and right sides. Main work – Position the crash bar and attach the clamp to the frame tube. – Mount screws but do not tighten yet.

  • Page 98: Removing The Storage Compartment And Hanging It To One Side

    SERVICE WORK ON THE CHASSIS 11.14 Removing the storage compartment and hanging it to one side Preparatory work – Remove the seat. ( p. 93) Main work – Open the storage compartment. ( p. 51) – Remove screws – Carefully remove the storage compartment and swing it to the right. Place a cloth between the right fuel tank and the storage compartment to prevent damage.

  • Page 99: Removing The Left Fuel Tank

    SERVICE WORK ON THE CHASSIS 11.16 Removing the left fuel tank 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.

  • Page 100: Installing The Left Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Remove screws – Lift the fuel tank slightly at the front, detach at the upper bracket and swing away from the vehicle at the top. Info Hold the fuel tank at roughly its installation height. Before it can be completely removed, several hoses and plug-in connections need to be detached.
  • Page 101 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 102: Checking For Chain Dirt

    SERVICE WORK ON THE CHASSIS Finishing work – Install the storage compartment. p. 96) – Close the storage compartment. ( p. 52) – Mount the seat. ( p. 93) – Install the front side cover. ( p. 90) – Turn the knurled screws on both fuel taps counterclockwise as far as possible. –...
  • Page 103 SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 104: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.20 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

  • Page 105: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.21 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.
  • Page 106 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 35… 40 mm (1.38… 1.57 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 107: Checking The Chain, Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 11.22 Checking the chain, rear sprocket and engine sprocket Preparatory work – Raise the vehicle using the center stand. ( p. 86) Main work – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: –...
  • Page 108 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 109 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the chain sliding guard is worn: – Change the chain sliding guard. – Check the chain sliding guard for tightness. » If the chain sliding guard is loose: –...

  • Page 110: Adjusting The Basic Setting Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11.23 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.

  • Page 111: Removing The Right Underride Guard

    SERVICE WORK ON THE CHASSIS – Position the cover with the membrane. Mount and tighten the screws. 11.25 Removing the right underride guard – Remove screws . Remove the right underride guard 100581-10 11.26 Installing the right underride guard – Position right underride guard .

  • Page 112: Removing The Underride Guard

    SERVICE WORK ON THE CHASSIS 11.27 Removing the underride guard Preparatory work – Raise the vehicle using the center stand. ( p. 86) Main work – Swing the side stand downward. – Remove all four screws and take off underride guard 100577-10 11.28 Installing the underride guard...

  • Page 113: Brake System

    BRAKE SYSTEM 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.

  • Page 114: 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 in several places to ensure that it...

  • Page 115: Checking The Front Brake Fluid Level

    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 116: Adding Front 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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 117: 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 118: Checking The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM – Check all brake linings on both brake calipers to ensure they have minimum thick- ness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. –...

  • Page 119: Checking The Rear Brake Fluid Level

    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.) – Raise the vehicle using the center stand. ( p.
  • Page 120 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 121: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 100562-10 12.10 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.)
  • Page 122 BRAKE SYSTEM 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 destroyed. Check the brake linings regularly. –...

  • Page 123: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the vehicle using the center stand. ( p. 86) Main work – Bear down on the rear of the vehicle or raise it on the underride guard. The front wheel is not in contact with the ground. –...

  • Page 124: Installing The Front Wheel

    WHEELS, TIRES – Remove spacers B01373-10 13.2 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 125: Removing The Rear Wheel

    WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft) – Raise the vehicle off of the center stand. ( p.
  • Page 126 WHEELS, TIRES – Remove nut . Remove chain adjuster B01375-10 – 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 127: Installing The Rear Wheel

    WHEELS, TIRES 13.4 Installing the rear 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. Warning Danger of accidents No braking effect when operating the rear brake.

  • Page 128: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – Mount the wheel spindle but do not push it in all the way. – Push the rear wheel as far forward as possible and place the chain on the rear sprocket. – Push the wheel spindle in all the way and mount chain adjuster and nut Info Mount chain adjuster...
  • Page 129 WHEELS, TIRES Preparatory work – Raise the vehicle using the center stand. ( p. 86) – Remove the rear wheel. p. 123) 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 130: 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 131: 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 132: 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 cause wheel imbalance, leading to more loose spokes in a short time.
  • Page 133 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 134: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing 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 135: Installing The Battery

    ELECTRICAL SYSTEM – Disconnect the negative (minus) cable of the battery. – Disconnect the positive (plus) cable of the battery. – Take the battery out of the battery compartment with battery tray Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety equipment can be damaged.

  • Page 136: Recharging The Battery

    ELECTRICAL SYSTEM – Hook cover into the battery compartment at the bottom and swing up. – Mount and tighten screws 100579-11 Finishing work – Install the underride guard. p. 110) – Raise the vehicle off of the center stand. ( p.
  • Page 137 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 casing.

  • Page 138: Changing The Main Fuse

    ELECTRICAL SYSTEM Main work – Pull off the red protection cap of the positive terminal extension. – Connect the positive cable of the charger to the positive terminal extension and the negative cable to an unpainted point on the engine .
  • Page 139 ELECTRICAL SYSTEM Info The main fuse is located in the starter relay under the right underride guard. Preparatory work – Switch off all power consumers and the engine. – Remove the right underride guard. ( p. 109) Main work – Pull starter relay off of the holder and remove protective cover 100583-10...

  • Page 140: Changing The Fuses In The Fuse Box

    ELECTRICAL SYSTEM Place the spare fuse in the starter relay so that it is available if needed. Finishing work – Install the right underride guard. ( p. 109) – Set the clock. ( p. 42) 14.5 Changing the fuses in the fuse box Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used.
  • Page 141 ELECTRICAL SYSTEM Main work – Remove fuse box cover 100587-10 – Remove the faulty fuse. Guideline Fuse IGNITION, FUEL PUMP - 10 A - ignition, fuel pump, immobilizer, alarm system (optional) Fuse H/L BEAM, POSITION - 15 A - high beam, low beam, parking light, license plate lamp Fuse HORN, BRAKE LIGHT - 10 A - horn, brake light, hazard warning flasher Fuse FAN - 10 A - radiator fan...

  • Page 142: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Use spare fuses with the correct rating only. Fuse (58011109110) ( p. 202) Fuse (58011109115) ( p. 202) Info Spare fuses are located next to the fuse box. Replace the spare fuse in the fuse box so that it is available if needed. 100637-10 –...

  • Page 143: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Disconnect plug-in connector – Place the headlight mask down on a soft cloth to prevent the headlight and trim disc from being damaged. 100591-10 14.7 Installing the headlight mask with the headlight Main work – Connect plug-in connector –...

  • Page 144: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 14.8 Changing the headlight 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. Preparatory work –...

  • Page 145: Changing The Parking Light Bulb In The Headlight

    ELECTRICAL SYSTEM – Turn holding ring counterclockwise all the way and take bulb out of the headlight. – Position the new bulb in the headlight and fix it with the holding ring. Low beam/high beam (H4 / socket P43t) ( p.

  • Page 146: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM Main work – Remove rubber cap – Pull socket out of the headlight and pull bulb out of the socket. – Insert the new bulb into the socket and insert the socket into the headlight. Parking light (W5W / socket W2.1x9.5d) ( p.

  • Page 147: Changing The Tail 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. Info Do not touch the reflector with your fingers, and keep it free from grease. –...

  • Page 148: Changing The Brake Light Bulb

    ELECTRICAL SYSTEM – Remove nuts at the bottom of the rear fender and pull out the tail light toward the rear. 100599-10 – Pull bulb sockets out of the tail light. – Pull bulbs out of the sockets. – Insert new bulbs into the sockets. Tail light (W5W / socket W2.1x9.5d) ( p.
  • Page 149 ELECTRICAL SYSTEM – Remove nuts at the bottom of the rear fender and pull out the tail light toward the rear. 100599-10 – Turn bulb socket counterclockwise all the way and take it out of the tail light. – Press bulb carefully into the socket, turn it counterclockwise by about 30°, and pull it out of the socket.

  • Page 150: Checking The Headlight Setting

    ELECTRICAL SYSTEM 14.13 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark 0 0 A at the height of the center of the low beam headlight. – Make another mark at a distance of under the first mark.

  • Page 151: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM Main work – Turn adjusting 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 headlight adjustment).
  • Page 152 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. – Turn the emergency OFF switch to the position 401114-10 – Insert the orange programming key in the ignition lock.
  • Page 153 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. In this case, twice. – Switch off the ignition by turning the orange programming key to the OFF position –...
  • Page 154 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 155 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 156: Cooling System

    COOLING SYSTEM 15.1 Cooling system 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) 100608-10 Cooling takes place by means of the air stream and a radiator fan...

  • Page 157: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM A radiator guard is included with the vehicle. The radiator guard should be mounted when operating the vehicle offroad. It prevents damage to the radiator from flying stones and similar causes. 0 0 4 100640-10 15.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
  • Page 158 COOLING SYSTEM Only remove the right side cover. Main work – Park the motorcycle upright on a horizontal surface. – Remove cap of the compensating tank. – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the antifreeze does not meet specifications: –...
  • Page 159 COOLING SYSTEM – Remove radiator cap – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the antifreeze does not meet specifications: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled. B00895-10 »...

  • Page 160: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM – Mount the radiator cap. Finishing work – Install the front side cover. ( p. 90) 15.3 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...

  • Page 161: Draining The Coolant

    COOLING SYSTEM – Park the motorcycle on a horizontal surface. – Check the coolant level in the compensating tank The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! B01380-10...
  • Page 162 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 163: Filling/Bleeding The Cooling System

    COOLING SYSTEM – Place a suitable container under the engine. – Remove screw – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 100611-10 15.5 Filling/bleeding the cooling system Warning...
  • Page 164 COOLING SYSTEM – Ensure that the drain plug on the radiator and the water pump cover are tightened. – Remove bleeder screw B00896-10 – Position the vehicle as shown and secure it against rolling. Height difference must be reached. Guideline Height difference 50 cm (19.7 in) Info...
  • Page 165 COOLING SYSTEM – Check the coolant level in the compensating tank. ( p. 158) 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 166: Tuning The Engine

    TUNING THE ENGINE 16.1 Checking the play in the throttle cable – 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 167: Adjusting The Play In The Throttle Cable

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

  • Page 168: Adjusting The Ignition Curve To The Fuel Quality

    TUNING THE ENGINE 16.4 Adjusting the ignition curve to the fuel quality Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF – Remove the seat. ( p. 93) To activate the ignition curve for low octane fuel: Note Engine failure Low-quality fuel damages the engine.

  • Page 169: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Preparatory work – Raise the vehicle using the center stand. ( p. 86) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. –...

  • Page 170: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain engine oil, clean oil screens. p. 168) – Install the oil filter. p. 173) – Install the left fuel tank. p. 98) –...
  • Page 171 SERVICE WORK ON THE ENGINE – Remove the underride guard. p. 110) – Switch off all power consumers and switch off the engine. – Remove the crash bar. p. 94) – Turn the knurled screws on both fuel taps clockwise as far as possible. –...
  • Page 172 SERVICE WORK ON THE ENGINE – Raise the vehicle off of the center stand. ( p. 87) – Lean the vehicle on the side stand. – Place a suitable container under the engine. – Remove oil drain plug – Fully drain the engine oil out of the oil tank. –...
  • Page 173 SERVICE WORK ON THE ENGINE Guideline Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft) – Mount oil drain plug with the magnet and new seal ring and tighten. Guideline Oil drain plug with magnet M22x1.5 35 Nm (25.8 lbf ft) –...

  • Page 174: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE 17.4 Removing the oil filter 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 175: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE – 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. B01382-10 17.5 Installing the oil filter – Insert oil filter –...
  • Page 176 SERVICE WORK ON THE ENGINE – The oil must be added in two steps. Engine oil 3.0 l (3.2 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 212) External Engine oil (SAE temperature: 5W/40) ( p.

  • Page 177: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the oil dipstick and wipe it off with a cloth. – Add engine oil to the MAX marking on the oil dipstick. Engine oil (2nd 0.50 l (0.53 qt.) External Engine oil quantity) approx. temperature: (SAE 10W/50) ≥...
  • Page 178 SERVICE WORK ON THE ENGINE Info For optimal performance of the engine oil, do not mix different types of engine oil. We recommend changing the engine oil, if necessary. – Replace the oil dipstick.

  • Page 179: Cleaning, Care

    CLEANING, CARE 18.1 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 180 CLEANING, CARE Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.

  • Page 181: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE High-luster polish for paint ( p. 216) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 216) –...
  • Page 182 CLEANING, CARE Info To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs. – Clean the chain. ( p. 100)

  • Page 183: Storage

    STORAGE 19.1 Storage Info If you want to garage the motorcycle for a longer period, take the following actions. 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). In this way, you can avoid long workshop waiting times at the start of the new season.

  • Page 184: 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 185: Troubleshooting

    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. – Engine has too little power Air filter very dirty...
  • Page 186 Action – Engine has too little power Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Ignition curve for low octane fuel acti- Refuel with fuel with an octane rating of 95 or vated higher.
  • Page 187 TROUBLESHOOTING Faults Possible cause Action – Headlight and parking light not func- Fuse H/L BEAM, POSITION blown Change the fuses in the fuse box. ( p. 138) tioning – Turn signal, hazard warning flasher, Fuse HORN, BRAKE LIGHT blown Change the fuses in the fuse box. ( p.

  • Page 188: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Blink code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition Malfunction, ICU antenna Blink code of immobilizer indica-...
  • Page 189 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 enabled Blink code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption request from EFI control unit to ICU Blink code of immobilizer indica-...

  • Page 190: 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 Crankshaft sensor circuit - 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 191 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 192 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 System voltage - circuit fault...
  • Page 193 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 194 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 195 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 69 FI warning lamp (MIL) flashes 6x long, 9x short Error level condition Manifold absolute pressure sensor cylinder 2 - connection leaks 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...

  • Page 196: Technical Data

    TECHNICAL DATA 23.1 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 Idle speed 1,420… 1,520 rpm Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter Exhaust 33 mm (1.3 in)

  • Page 197: Engine Tightening Torques

    TECHNICAL DATA 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 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)
  • Page 198 TECHNICAL DATA – Remaining engine screws 10 Nm (7.4 lbf ft) – Screw in alternator cover 10 Nm (7.4 lbf ft) ® Screw, bearing bolt in alternator cover 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, camshaft bearing support 10 Nm (7.4 lbf ft) –...
  • Page 199 TECHNICAL DATA – Screw, clutch cover 15 Nm (11.1 lbf ft) ® Screw, cylinder head Step 1 Loctite 243™ 18 Nm (13.3 lbf ft) Step 2 23 Nm (17 lbf ft) ® Screw, timing chain guide rail 15 Nm (11.1 lbf ft) Loctite 243™...

  • Page 200: Capacities

    TECHNICAL DATA – Engine coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) – Plus, cylinder head (2nd cylinder) M12x1.5 25 Nm (18.4 lbf ft) ® Plug, oil filter housing M14x1.5 15 Nm (11.1 lbf ft) Loctite 243™ ® Bleeder flange, alternator cover M16x1.5 10 Nm (7.4 lbf ft) Loctite...

  • Page 201: Fuel

    TECHNICAL DATA 23.3.3 Fuel Total fuel tank capacity, approx. 20 l (5.3 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 214) Fuel reserve, approx. 4 l (1.1 US gal)

  • Page 202: Chassis

    CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated WP Suspension Up Side Down 4860 MXMA PA Fork WP Suspension PDS 5018 DCC PA Shock absorber Suspension travel Front 210 mm (8.27 in) Suspension travel Rear 210 mm (8.27 in) Brake system Front Double disk brake with floating brake calipers and brake discs...
  • Page 203 CHASSIS Secondary drive ratio 16:42 Chain 5/8 x 5/16” X‑ring Steering head angle 63.4° Wheelbase 1,570 mm (61.81 in) Seat height, unloaded 860 mm (33.86 in) Ground clearance, unloaded 261 mm (10.28 in) Weight without fuel, approx. 207 kg (456 lb.) Maximum permissible front axle load 200 kg (441 lb.) Maximum permissible rear axle load...

  • Page 204: Electrical System

    ELECTRICAL SYSTEM Battery YTZ14S Battery voltage: 12 V Nominal capacity: 11.2 Ah maintenance-free Fuse 58011109110 10 A Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 58011109140 40 A Low beam/high beam H4 / socket P43t 12 V 60/55 W Parking light...

  • Page 205: Tires

    TIRES Front tires Rear tires 90/90 - 21 M/C 54R TT 140/80 - 18 M/C 70R TT Dunlop Rally Raid D 908 F RR Dunlop Rally Raid D 908 RR Additional information is available in the Service section under: http://www.ktm.com...

  • Page 206: Fork

    FORK Fork part number 14.18.7E.24 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload - Preload Adjuster...
  • Page 207 FORK Fork oil per fork leg 655 ml (22.15 fl. oz.) Fork oil (SAE 5) ( p. 213)

  • Page 208: Shock Absorber

    SHOCK ABSORBER Shock absorber part number 12.18.7E.08 Shock absorber WP Suspension PDS 5018 DCC PA 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 Full payload...
  • Page 209 SHOCK ABSORBER Spring length 225 mm (8.86 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Fitted length 372 mm (14.65 in) Shock absorber oil ( p. 213) SAE 2.5...

  • Page 210: Chassis Tightening Torques

    CHASSIS TIGHTENING TORQUES – Screw, side stand switch 2 Nm (1.5 lbf ft) – Screw, filler cap 5 Nm (3.7 lbf ft) ® Screw, foot brake lever stub 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, fuel level indicator 3 Nm (2.2 lbf ft) –...
  • Page 211 CHASSIS TIGHTENING TORQUES – Nut, manifold on cylinder head Tightening sequence: Tighten the nuts evenly. Do not bend the metal. – Remaining chassis nuts 25 Nm (18.4 lbf ft) – Remaining chassis screws 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) –...
  • Page 212 CHASSIS TIGHTENING TORQUES ® Screw, side stand bracket 45 Nm (33.2 lbf ft) Loctite 243™ ® Screw, side stand holding plate 40 Nm (29.5 lbf ft) Loctite 243™ ® Nut, rear sprocket screw M10x1.25 50 Nm (36.9 lbf ft) Loctite 243™...

  • Page 213: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – 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 –...
  • Page 214 SAE ( p. 218) (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 215 Hydraulic fluid (15) According to – 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 ® –...
  • Page 216 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 217: 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 218 AUXILIARY SUBSTANCES High-luster polish for paint Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Polish Long-life grease Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex ®...
  • Page 219 AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...
  • Page 220 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 221 INDEX INDEX Capacity Accessories ........22 coolant .
  • Page 222 INDEX kilometers or miles, setting ..... . 41 Engine overview ........37 running in .
  • Page 223 INDEX removing ........140 Fork part number .
  • Page 224 INDEX removing ........91 Rear hub rubber dampers Oil filter checking .
  • Page 225 INDEX rebound damping, adjusting ..... . 83 Tail light bulb spring preload, adjusting ......84 changing .
  • Page 226 INDEX Underride guard installing ........110 removing ........110 Underride guard, right installing .
  • Page 227 *3211908en* 3211908en 12/2012 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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