KTM 125 Duke Owner's Manual
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KTM 125 Duke Owner's Manual

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OWNER'S MANUAL
2011
125 Duke EU
Art. no. 3211668en

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Summary of Contents for KTM 125 Duke

  • Page 1 OWNER'S MANUAL 2011 125 Duke EU Art. no. 3211668en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you DEAR KTM CUSTOMER enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below.
  • 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 Combination instrument - warning notes ......32 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........6 Riding time/average speed menu........34 IMPORTANT INFORMATION ........... 7 Average speed/service menu ..........34 VIEW OF VEHICLE..............12 Service/riding time menu ..........35 View of vehicle, front left (example)........
  • Page 6 TABLE OF CONTENTS Applying the brakes ............55 Checking the rear brake fluid level ........80 Stopping, parking ............. 56 Adding rear brake fluid ..........81 Refueling................. 58 Checking the free travel of foot brake lever......83 SERVICE SCHEDULE............60 Adjusting the free travel of the foot brake lever ....
  • Page 7 TABLE OF CONTENTS TUNING THE ENGINE ............117 AUXILIARY SUBSTANCES........... 148 Checking the play in the throttle cable......117 STANDARDS..............150 INDEX ................151 Adjusting the play in the throttle cable ......118 Checking the clutch lever play ......... 118 Adjusting the clutch cable play ........

  • Page 8: Means Of Representation

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

  • Page 9: Important Information

    IMPORTANT INFORMATION Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.
  • Page 10 Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 11 IMPORTANT INFORMATION – Use straps or other suitable devices to secure the motorcycle against falling over and rolling away. Environment If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
  • Page 12 IMPORTANT INFORMATION Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) B00778-10...
  • Page 15 VIEW OF VEHICLE Combination instrument Rear mirror Clutch lever ( p. 18) Seat Passenger seat Seat lock ( p. 42) Grab handles ( p. 43) Engine number ( p. 16) Side stand ( p. 46) Shift lever ( p. 44)

  • Page 16: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) B00779-10...
  • Page 17 VIEW OF VEHICLE Tool set ( p. 43) Light switch ( p. 19) High beam flasher button ( p. 20) Turn signal switch ( p. 20) Horn button ( p. 21) Filler cap Ignition/steering lock ( p. 22) Emergency OFF switch ( p.

  • Page 18: Serial Numbers

    SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the right of the steering head.  The type label is on the right of the frame behind the steering head.  B00699-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. ...

  • Page 19: Key Number

    SERIAL NUMBERS Key number The 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. B00755-10...

  • Page 20: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  B00701-10 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. B00702-10...

  • Page 21: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar.  B00703-10 Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on.

  • Page 22: High Beam Flasher Button

    CONTROLS High beam flasher button The high beam flasher button is fitted on the left side of the handlebar.  Possible states • High beam flasher button in neutral position High beam flasher button pressed – In this position, the headlight flasher (high beam) •...

  • Page 23: Horn Button

    CONTROLS 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. • Horn button B00706-11 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 24: 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 – In this position, the electric starter is actuated. • Electric starter button B00708-10 Ignition/steering lock 5.10...

  • Page 25: Combination Instrument - Overview

    CONTROLS Combination instrument - overview 5.11 Combination instrument - display ( p. 27) Combination instrument - function buttons ( p. 25) Combination instrument - info display ( p. 31) Combination instrument - indicator lamps ( p. 26) 401289-10...

  • Page 26: Combination Instrument - Activation And Test

    CONTROLS Combination instrument - activation and test 5.12 Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up briefly.

  • 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 total distance traveled (TRIP 1), distance 1 (ODO) and distance 2 (TRIP 2). Pressing and holding the SET button resets the distance 1 (TRIP 1) and ...

  • Page 28: Combination Instrument - Indicator Lamps

    CONTROLS Combination instrument - indicator lamps 5.14 Possible states The turn signal indicator light flashes green simultaneously with the turn signals – Turn signal is switched on. The engine diagnosis warning lamp (MIL) lights up red – The OBD (onboard diagnosis) has identified an emissions- or safety-critical fault.

  • Page 29: Combination Instrument - Display

    CONTROLS Combination instrument - display 5.15 The speed is shown in kilometers per hour km/h or in miles per hour mph.  The tachometer shows the engine speed in revolutions per minute.  The gear display shows the engaged gear. ...

  • Page 30: Combination Instrument - Filling Level Display In Fuel Tank

    CONTROLS Combination instrument - filling level display in fuel tank 5.16 The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank. 401292-01...

  • Page 31: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.17 If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note Low Fuel Level appears on the info display.

  • Page 32: Combination Instrument - Coolant Temperature Indicator

    CONTROLS Combination instrument - coolant temperature indicator 5.18 The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Coolant Temperature. Possible states Engine cold –...

  • Page 33: Combination Instrument - Info Display

    CONTROLS Combination instrument - info display 5.19 Various warning notes appear on info display  If the general warning lamp lights up, the corresponding warning note is shown on the info display. 401291-10...

  • Page 34: Combination Instrument - Warning Notes

    CONTROLS Combination instrument - warning notes 5.20 Low Oil Pressure appears on the info display if the oil pressure is too low. 401309-01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark. 401310-01...
  • Page 35 CONTROLS High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 125 °C (257 °F) 401311-01 Side Stand Down appears on the info display if the side stand is folded down. 401312-01 Low Battery appears on the info display if the battery voltage falls below the specified value.

  • Page 36: Riding Time/Average Speed Menu

    CONTROLS Riding time/average speed menu 5.21 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed in this menu.

  • Page 37: Service/Riding Time Menu

    CONTROLS Press the SET button Next display mode on the info display briefly. Service/riding time menu 5.23 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. –...

  • Page 38: Distance Menu 1 Trip 1

    CONTROLS Info This value is retained, even if the battery is disconnected and/or the fuse blows. Press the MODE but- Next display mode on the display ton. Distance menu 1 TRIP 1 5.25 Condition Alternative 1 • The ignition is on. •...

  • Page 39: Distance Menu 2 Trip 2

    CONTROLS Distance menu 2 TRIP 2 5.26 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. TRIP 2 shows the distance covered since the last reset.

  • Page 40: Setting The Time

    CONTROLS – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE button for 5 - 10 seconds. The display changes from km/h to mph or from mph to km/h. 401303-01 Setting the time 5.28 Condition The ignition is on.

  • Page 41: Adjusting The Shift Speed Rpm 1

    CONTROLS Adjusting the shift speed RPM 1 5.29 Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the MODE button for 5 - 10 seconds. The display RPM 1 appears.

  • Page 42: Opening The Filler Cap

    CONTROLS – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the SET button for 5 - 10 seconds. The display RPM 2 appears. Info The engine speed can be set at intervals of 50. RPM 2 is the engine speed above which the shift warning light lights up con- stantly.
  • Page 43 CONTROLS 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 44: Closing The Filler Cap

    CONTROLS Closing the filler cap 5.32 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 45: Tool Set

    CONTROLS Tool set 5.34 The tool set is located under the passenger seat.  B00758-10 Grab handles 5.35 The grab handles are used for moving the motorcycle around.  If you carry a passenger, the passenger can hold onto the grab handles during the trip. B00717-10...

  • Page 46: Passenger Footrests

    CONTROLS Passenger footrests 5.36 The passenger footrests can be folded in and out. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • B00713-01 Shift lever 5.37 Shift lever is mounted on the left side of the engine.

  • Page 47: 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. B00716-10 Foot brake lever 5.38 Foot brake lever is located in front of the right footrest.  The foot brake lever is used to activate the rear brake. B00718-10...

  • Page 48: Side Stand

    CONTROLS Side stand 5.39 The side stand is 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 49: 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 50: 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 51 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 Risk of breakage of suitcase system. –...

  • Page 52: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance 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 used. – Check the engine oil level. ( p.

  • Page 53: 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 54: Starting Off

    RIDING INSTRUCTIONS – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 55: Shifting, Riding

    RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –...
  • Page 56 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

  • Page 57: Applying The Brakes

    Switch off the engine if you expect to be standing for a long time. – If the engine diagnosis warning lamp lights up during a trip, stop immediately, switch off the engine, and contact an authorized KTM workshop. Applying the brakes Warning Danger of accidents If you brake too hard, the wheels can lock.

  • Page 58: Stopping, Parking

    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 Longer stopping distance due to higher overall weight.
  • Page 59 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 brakes. 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 60: Refueling

    – 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 61 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 40) – Fill the fuel tank with fuel up to the lower edge of the fuel filler.  Total fuel tank 10.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 62: Service Schedule

    Check the functioning of the electrical equipment. • • • • • • Read out the fault memory using the KTM diagnostics tool. • • • Change the engine oil and oil filter, clean the oil screen. p. 120) Check the front brake linings. ( p.
  • Page 63 • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record. K10N: Once after 1,000 km (621.4 mi)

  • Page 64: Tuning The Chassis

    TUNING THE CHASSIS Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial situation of the spring process on the shock absorber.
  • Page 65 TUNING THE CHASSIS – Loosen nuts  – Adjust the shift lever by turning shift rod  Guideline Shift rod adjustment range 100… 112 mm (3.94… 4.41 in)  Info Make the same adjustments on both sides. At least five screw threads must be screwed into the seating. –...

  • Page 66: 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. – Raise the motorcycle with the rear wheel stand. ( p.

  • Page 67: Raising The Motorcycle With The Rear Wheel Stand

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the front wheel stand. B00781-01 Raising the motorcycle with the rear wheel stand 10.3 Note Danger of damage The parked vehicle may roll away or fall over. –...

  • Page 68: Taking The Motorcycle Off Of The Rear Wheel Stand

    SERVICE WORK ON THE CHASSIS Taking the motorcycle off of the rear wheel stand 10.4 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. –...

  • Page 69: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS Mounting the passenger seat 10.6 – Attach hooks on the passenger seat to brackets on the subframe, and lower it at   the rear while pushing forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 70: Mounting The Seat

    SERVICE WORK ON THE CHASSIS Mounting the seat 10.8 – Attach seat recesses at screws and lower at the rear.   – Mount and tighten screws  Guideline Screw, seat 15 Nm (11.1 lbf ft) – Mount the passenger seat. ( p.

  • Page 71: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS Checking for chain dirt accumulation 10.9 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 69) 400678-01 Cleaning the chain 10.10 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 72: 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 73: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear 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.
  • Page 74 SERVICE WORK ON THE CHASSIS – Check the chain tension. ( p. 70) – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 5… 7 mm (0.2… 0.28 in) Turn adjusting screws on the left and right so that the markings on the left and ...

  • Page 75: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS Checking the chain, rear sprocket, and engine sprocket 10.13 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
  • Page 76 SERVICE WORK ON THE CHASSIS – Shift gear to neutral. – Pull the lower chain section with specified weight  Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 20 chain links in the lower chain section. ...

  • Page 77: Removing The Front Spoiler

    SERVICE WORK ON THE CHASSIS Removing the front spoiler 10.14 – Remove screws  B00770-10 – Remove screws  – Take off the front spoiler. B00771-10...

  • Page 78: Fitting Front Spoiler

    SERVICE WORK ON THE CHASSIS Fitting front spoiler 10.15 – Position the front spoiler. Mount screws but do not tighten yet.  B00770-10 – Mount and tighten screws  – Tighten screw  B00771-10...

  • Page 79: Brakes

    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 80: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear 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 81 Warning Danger of accidents Reduced braking effect caused by 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 82: Checking The Front Brake Linings

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

  • Page 83: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by 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 84 Warning Danger of accidents Reduced braking effect caused by 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 85: Checking The Free Travel Of Foot Brake Lever

    BRAKES Checking the free travel of foot brake lever 11.7 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.

  • Page 86: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKES Adjusting the free travel of the foot brake lever 11.8 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.

  • Page 87: Checking The Rear Brake Linings

    11.9 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 reduced and the brake discs are rendered unserviceable.

  • Page 88: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 – Raise the motorcycle with the rear wheel stand. ( p. 65) – Raise the motorcycle with the front wheel stand. ( p. 64) – Loosen screw and screws   – Unscrew screw about six turns and press your hand on the screw to push the wheel ...
  • Page 89 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers.  ...

  • Page 90: Removing The Rear Wheel

    WHEELS, TIRES Removing the rear wheel 12.3 – Raise the motorcycle with the rear wheel stand. ( p. 65) – Remove nut and the washer. Remove chain adjuster   – Holding the rear wheel, withdraw wheel spindle  – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
  • Page 91 WHEELS, TIRES Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. – Check the rear hub rubber dampers. p. 90) – Check the wheel bearing for damage and wear.

  • Page 92: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – Pull the rear wheel back and mount wheel spindle  Info Mount the left and right chain adjusters in the same position.  – Mount nut and washer.  – Push the rear wheel forward so that the chain adjusters are on the screws, and tighten ...

  • Page 93: Checking The Tire Condition

    88) Checking the tire condition 12.6 Warning 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.)
  • Page 94 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. Info The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.

  • Page 95: 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 are changed regardless of the actual wear, at the latest after 5 years.
  • Page 96 WHEELS, TIRES – Mount the dust cap.

  • Page 97: 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 98: Installing The Battery

    ELECTRICAL SYSTEM – Pull back the positive terminal cover  – Disconnect the positive cable of the battery.  – Detach rubber band  – Pull the battery up and out of the battery rack. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged.

  • Page 99: Recharging The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – 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.
  • Page 100 ELECTRICAL SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery.

  • Page 101: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid ...
  • Page 102 ELECTRICAL SYSTEM – Open fuse box cover  B00753-10 – Remove the defective fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 15 A - combination instrument Fuse 3 - 10 A - control unit, main relay Fuse 4 - 15 A - ignition coil, alarm system (OPTIONAL) Fuse 5 - 15 A - radiator fan Fuse 6 - 15 A - horn, brake light, turn signal, high beam, low beam, parking light, tail...

  • Page 103: Changing The Headlight Bulb

    ELECTRICAL SYSTEM – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 137) Fuse (75011088015) ( p. 137) Fuse (75011088030) ( p. 137) Replace the spare fuse in the fuse box so that it is available if needed. –...
  • Page 104 ELECTRICAL SYSTEM – Remove screws  – Remove expanding rivets on both sides.  – Fold the headlight mask forward. B00759-10 – Take off rubber cap  – Disconnect plug-in connector  B00760-10 – Detach retaining clamp  – Remove headlight bulb ...

  • Page 105: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Attach retaining clamp  – Connect plug-in connection  – Mount rubber cap  B00760-10 – Fold the headlight mask up. – Mount and tighten screws  Guideline Screw, headlight mask 14 Nm (10.3 lbf ft) – Mount expanding rivets on both sides.
  • Page 106 ELECTRICAL SYSTEM – Switch off all power consumers and switch off the engine. – Remove screws  – Remove expanding rivets on both sides.  – Fold the headlight mask forward. B00759-10 – Remove screws  – Take off cover ...
  • Page 107 ELECTRICAL SYSTEM – Pull parking light out of the holder.  – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9.5d) ( p. 137) – Carefully position the socket with bulb into the bracket in the headlight. ...

  • Page 108: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Fold the headlight mask up. – Mount and tighten screws  Guideline Screw, headlight mask 14 Nm (10.3 lbf ft) – Mount expanding rivets on both sides.  – Check that the lighting is functioning properly. B00759-10 Checking the headlight setting 13.7 –...

  • Page 109: Adjusting The Headlight Range

    ELECTRICAL SYSTEM » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 107) Adjusting the headlight range 13.8 – Remove screws  – Remove expanding rivets on both sides.  – Fold the headlight mask forward.
  • Page 110 ELECTRICAL SYSTEM – Fold the headlight mask up. – Mount and tighten screws  Guideline Screw, headlight mask 14 Nm (10.3 lbf ft) – Mount expanding rivets on both sides.  – Check the headlight setting. ( p. 106) B00759-10...

  • Page 111: Cooling System

    COOLING SYSTEM Cooling system 14.1 Water pump in the engine circulates the coolant.  The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank ...

  • Page 112: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther-  moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 401287-10 Checking the antifreeze and coolant level 14.2...
  • Page 113 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 114: Checking The Coolant Level

    COOLING SYSTEM – Screw off radiator cap  – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled.
  • Page 115 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 116: Draining The Coolant

    COOLING SYSTEM » If you had to add more coolant than the specified amount: > 0.20 l (> 0.21 qt.) – Fill/bleed the cooling system. p. 115) – Mount the radiator cap. Draining the coolant 14.4 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...

  • Page 117: Filling/Bleeding The Cooling System

    COOLING SYSTEM Filling/bleeding the cooling system 14.5 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 118 COOLING SYSTEM – Rest the vehicle on the side stand. 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 119: 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. Throttle cable play 3…...

  • Page 120: Adjusting The Play In The Throttle Cable

    TUNING THE ENGINE Adjusting the play in the throttle cable 15.2 – Move the handlebar to the straight-ahead position. – Push back sleeve  – Loosen lock nut  – Adjust the play in the throttle cable by turning adjusting screw ...

  • Page 121: Adjusting The Clutch Cable Play X

    TUNING THE ENGINE » If the clutch lever play changes: – Check the routing of the clutch cable. Adjusting the clutch cable play 15.4 – Move the handlebar to the straight-ahead position. – Push back sleeve  – Loosen lock nut ...

  • Page 122: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Condition The engine is at operating temperature. – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer.
  • Page 123 SERVICE WORK ON THE ENGINE – Remove the front spoiler. ( p. 75) – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove oil drain plug and oil screen ...
  • Page 124 SERVICE WORK ON THE ENGINE – Insert oil filter  – Oil the O-ring of the oil filter cover. Mount oil filter cover  – Mount and tighten the screws. Guideline Screw, oil filter cover 12 Nm Loctite ® 243™ (8.9 lbf ft) Info Too little engine oil or poor-quality engine oil results in premature wear to the...

  • Page 125: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Check the engine oil level. ( p. 120) Adding engine oil 16.3 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the oil filler plug with the O-ring from the clutch cover and fill up with ...

  • Page 126: Cleaning, Care

    CLEANING, CARE Cleaning the 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 127 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. 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 128: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Checks and maintenance steps for winter operation 17.2 Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corrosion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 129: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 65) –...

  • Page 130: Preparing For Use After Storage

    STORAGE – Cover the motorcycle with a tarp or similar 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 131: Troubleshooting

    Operating error Go through the steps of starting the engine. p. 51) – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter is very dirty Change the air filter.
  • Page 132 Defect in radiator fan system Check the radiator fan system. – The engine diagnosis warning Defect in fuel injection system Read out the fault memory using the KTM diag- lamp (MIL) lights up red nostics tool. – Engine dies during the trip Lack of fuel Refuel.
  • Page 133 TROUBLESHOOTING Faults Possible cause Action – Speedometer in combination instru- Speedometer wiring harness is dam- Check the wiring harness and plug-in connection. ment not functioning aged or plug-in connection is oxidized...

  • Page 134: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement 124.7 cm³ (7.61 cu in) Stroke 47.2 mm (1.858 in) Bore 58 mm (2.28 in) Compression ratio 12.8:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 22.5 mm (0.886 in) Valve diameter, exhaust 19 mm (0.75 in)

  • Page 135: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 238 W Spark plug BOSCH VR 5 NC Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump Idle speed 1,350…...

  • Page 136: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil jet 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, engine vent plate 7 Nm (5.2 lbf ft) Loctite 243™ ® Screw, oil filter cover 12 Nm (8.9 lbf ft) Loctite 243™ ®...
  • Page 137 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, timing chain tensioning rail 12 Nm (8.9 lbf ft) Loctite 243™ – Screw, valve cover 12 Nm (8.9 lbf ft) – Screw, water pump cover 12 Nm (8.9 lbf ft) – Nut, connecting rod screw 24 Nm (17.7 lbf ft) –...

  • Page 138: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame of steel tubes, powder-coated Fork WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with dual-piston brake caliper Rear Disc brake with single-piston brake caliper, floating Suspension travel Front 150 mm (5.91 in) Rear 150 mm (5.91 in) Brake discs - diameter...

  • Page 139: Lighting Equipment

    TECHNICAL DATA - CHASSIS Seat height, unloaded 810 mm (31.89 in) Ground clearance, unloaded 170 mm (6.69 in) Weight without fuel, approx. 125 kg (276 lb.) Battery FTZ-7 Battery voltage: 12 V Nominal capacity: 6 Ah Maintenance-free Fuse 75011088010 10 A Fuse 75011088015 15 A...

  • Page 140: Tires

    110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 22.3 Total fuel tank capacity, approx. 10.5 l (2.77 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 141: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 90101000044 Fork WP Suspension Fork length 736 mm (28.98 in) Fork oil Fork oil (SAE 5) ( p. 147)

  • Page 142: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 90104010033 Shock absorber WP Suspension Spring preload Standard 3 clicks Full payload 6 clicks Static sag 25 mm (0.98 in) Riding sag 45… 50 mm (1.77… 1.97 in) Fitted length 300 mm (11.81 in)

  • Page 143: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, headlight EJOT 4 Nm (3 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) – Screw, control unit 4 Nm (3 lbf ft) – Screw, trim, subframe, bottom 2 Nm (1.5 lbf ft) –...
  • Page 144 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, cable holder, side stand switch 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, chain sliding guard 9 Nm (6.6 lbf ft) Loctite 243™ – Screw, front fender 11 Nm (8.1 lbf ft) –...
  • Page 145 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, foot brake lever 15 Nm (11.1 lbf ft) Loctite 243™ – Screw, fork stub 15 Nm (11.1 lbf ft) ® Screw, front brake disc 29 Nm (21.4 lbf ft) Loctite 243™ – Screw, front wheel spindle 25 Nm (18.4 lbf ft) –...
  • Page 146 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Nut, swingarm pivot M14x1.5 98 Nm (72.3 lbf ft)

  • Page 147: 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 148 SAE ( p. 150) (SAE 15W/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. Partially synthetic engine oil Supplier ® Motorex –...
  • Page 149 SAE ( p. 150) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper- ® ties. KTM recommends Motorex products. Supplier ® Motorex – Racing Fork Oil...
  • Page 150 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 151 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 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline –...
  • Page 152 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 153 INDEX checking ........73 INDEX cleaning ........69 Accessories .
  • Page 154 INDEX Coolant Filling up draining ........114 fuel .
  • Page 155 INDEX Parking light bulb changing ........103 Ignition lock .
  • Page 156 INDEX removing ........67 shock absorber ......140 Seat lock .
  • Page 157 *3211668en* 3211668en 04/2011 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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