KTM 1190 RC8 R EU/UK 2009 Repair Manual
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KTM 1190 RC8 R EU/UK 2009 Repair Manual

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REPAIR MANUAL
2009
1190 RC8 R EU/UK
1190 RC8 R AUS
1190 RC8 R FR
1190 RC8 R JP
Article no. 3206077en

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Summary of Contents for KTM 1190 RC8 R EU/UK 2009

  • Page 1 REPAIR MANUAL 2009 1190 RC8 R EU/UK 1190 RC8 R AUS 1190 RC8 R FR 1190 RC8 R JP Article no. 3206077en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    CONTENTS Servicing the shock absorber .......... 48 CONTENTS MEANS OF REPRESENTATION ..........6 Removing the spring ............48 IMPORTANT NOTES ............7 Disassembling the damper ..........49 LOCATION OF SERIAL NUMBERS ........8 Disassembling the piston rod .......... 50 Vehicle identification number/type label ......8 Checking the damper .............
  • Page 5 CONTENTS Fuel pump relay ............88 Removing the heat exchanger ........124 Removing the battery ............. 88 Removing the rear timing chain tensioner ...... 124 Installing the battery............89 Removing the rear camshaft ......... 125 Recharging the battery ........... 90 Removing the rear cylinder head ........
  • Page 6 CONTENTS Preparing the timing chain tensioner for installation ..154 Adjusting the front cylinder control time ......186 Checking the oil pressure regulator valve......155 Checking the front valve clearance ........ 187 Checking the oil pumps..........155 Adjusting the front valve clearance........ 188 Checking the clutch.............
  • Page 7 KTM-RC8 workshop........420 Ignition coil cylinder 2 connector AS ......394 Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) ..421 CAN bus terminating resistor connector AT ....395 WIRING DIAGRAM ............422 Crankshaft position sensor, connector AT.......

  • Page 8: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). Formats used The typographical formats used in this document are explained below.

  • Page 9: Important Notes

    Warranty The work described in the service schedule must be carried out exclusively in an authorized KTM-RC8 workshop and confirmed in the service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting from manipula- tion and/or other changes to the vehicle.

  • Page 10: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Vehicle identification number/type label The vehicle identification number is stamped on the frame behind the steering head  on the right. The type label is on the frame above the vehicle identification number.  100654-10 Key number The key number Code number can be found on the KEYCODECARD.

  • Page 11: Steering Damper Part Number

    LOCATION OF SERIAL NUMBERS Steering damper part number The steering damper part number is stamped on the top of the steering damper.  100658-10...

  • Page 12: Motorcycle

    MOTORCYCLE Jacking up motorcycle front Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle at the rear. ( p. 13) – Move the handlebar to the straight-ahead position.

  • Page 13: Removing The Motorcycle From The Work Stand (Screw-In Type)

    MOTORCYCLE – Screw the holder of the special tool all the way into the lower drill holes of the footrest brackets. Select the required height and width of the work stand. Work stand (62529055000) ( p. 447) – Jack up the motorcycle. Info Check that the work stand is seated correctly.

  • Page 14: Jacking Up The Motorcycle In The Middle (Insertable Type)

    MOTORCYCLE – Position the footrest bracket. Mount and tighten screws  Guideline Screw, front footrest 25 Nm Loctite ® 243™ bracket (18.4 lbf ft) – Position the shift rod. Mount and tighten screw  Guideline Screw, shift rod 12 Nm Loctite ®...

  • Page 15: Jacking Up Motorcycle At The Rear

    MOTORCYCLE – Remove the motorcycle from the work stand and rest it on the side stand. – Remove the work stand. Work stand (62529055000) ( p. 447) 200597-01 Jacking up motorcycle at the rear Note Danger of damage The parked vehicle can roll away or fall over. –...
  • Page 16 MOTORCYCLE Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. – Always warm up the engine at low engine speeds. – Press the emergency OFF switch into the position – Switch on the ignition by turning the black programming key to the position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 17: 01/Fork, Triple Clamp

    01/FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when the load shifts very fast.

  • Page 18: Adjusting The Spring Preload Of The Fork

    01/FORK, TRIPLE CLAMP Adjusting the spring preload of the fork Info Spring preload determines the initial fork position. The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and thus ensures a compromise between maneuverability and stability.

  • Page 19: Vehicle Level

    01/FORK, TRIPLE CLAMP Vehicle level 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. The vehicle level can be adjusted at the front by means of the fork leg clamp and at the rear by the eccentric shaft.

  • Page 20: Removing The Fork

    01/FORK, TRIPLE CLAMP – Tighten screw  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws  Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) 100694-11 – Tighten screw  Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) –...

  • Page 21: Installing The Fork

    01/FORK, TRIPLE CLAMP – Remove screws . Hang the wheel speed sensor to the side.  201058-10 – Unscrew screws of the triple clamps and handlebar stubs. Remove the fork legs  downward. 201059-10 Installing the fork Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. –...
  • Page 22 01/FORK, TRIPLE CLAMP – Position the fender. Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 201057-11 – Clean and grease the shaft seal rings and mating surfaces of the spacers.   Long-life grease ( p.

  • Page 23: Performing A Fork Service

    01/FORK, TRIPLE CLAMP – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Tighten screws  Guideline Fork end pinch bolts 15 Nm (11.1 lbf ft) 100782-11 performing a fork service Info These operations are the same on both fork legs.
  • Page 24 01/FORK, TRIPLE CLAMP – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T612S) ( p. 451) 200606-10 – Release Preload Adjuster  Key (T524) ( p. 450) Info The Preload Adjuster cannot be removed yet. –...
  • Page 25 01/FORK, TRIPLE CLAMP – Remove adjusting tube  200611-10 – Screw special tool onto the piston rod and pull it up.  Gripping tool (T14026S1) ( p. 449) – Remove the special tool from the hexagonal piece. Open-end wrench (T14032) ( p.

  • Page 26: Disassembling The Outer Tubes

    01/FORK, TRIPLE CLAMP – Clamp the fork leg with the axle clamp. – Remove screws  200616-10 – Unscrew screws of the cartridge and remove with the seal ring.  Info Place a drain pan underneath. 200617-10 – Remove the cartridge. 200618-10 Disassembling the outer tubes 5.11...

  • Page 27: Checking The Fork Legs

    01/FORK, TRIPLE CLAMP – Remove lock ring  200620-10 – Remove seal ring  200621-10 – Remove support ring  200622-10 Checking the fork legs 5.12 Condition The fork legs must be disassembled. – Check the inner tube and axle clamp for damage. »...

  • Page 28: Changing The Lower Du Bush

    01/FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Run-out of inner tube » If the measured value is greater than the specified value: – Change the inner tube. 200631-10 – Check the outer tube for damage. »...

  • Page 29: Assembling The Outer Tubes

    01/FORK, TRIPLE CLAMP Assembling the outer tubes 5.14 Info These operations are the same on both outer tubes. – Check the fork legs. ( p. 25) – Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T612S) ( p.
  • Page 30 01/FORK, TRIPLE CLAMP – Slide the cartridge into the inner tube with spring seat and the preload bush.  200618-11 – Clamp the fork leg with the axle clamp. – Mount and tighten screw  Guideline Screw, cartridge M12x1 25 Nm (18.4 lbf ft) 200626-10 –...
  • Page 31 01/FORK, TRIPLE CLAMP – Slide on collar bushing  – Slide adjusting tube into the piston rod.  200624-10 – Install the special tool. Gripping tool (T14026S1) ( p. 449) Info The special tool must be used to prevent the adjusting tube from being raised, which would cause oil to enter into the piston rod.
  • Page 32 01/FORK, TRIPLE CLAMP – Unscrew the special tool from the piston rod. Gripping tool (T14026S1) ( p. 449) – Lubricate the thread of the piston rod. Lubricant (T159) ( p. 438) – Lubricate the upper edge of the piston rod. Lubricant (T158) ( p.
  • Page 33 01/FORK, TRIPLE CLAMP Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Compression damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks – Turn the adjusting screw of spring preload all the way clockwise.

  • Page 34: 02/Handlebar, Controls And Instruments

    02/HANDLEBAR, CONTROLS AND INSTRUMENTS Adjusting basic position of 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 35: Adjusting The Play In The Throttle Cable

    Move the handlebar to the straight-ahead position. – Throttle position sensor circuit A - check in the "zero" position. ( p. 219) Info It is imperative to use the KTM diagnostics tool for this. – Push back protective cover  –...

  • Page 36: Throttle Grip

    The installed throttle grip has the marking 3081. The supplied throttle grip has the marking 5209. Info Resetting the throttle cable play is necessary after replacement has been carried out. It is imperative to use the KTM diagnostics tool for this. 100784-10 Changing the throttle grip –...
  • Page 37 02/HANDLEBAR, CONTROLS AND INSTRUMENTS – Turn the handlebar all the way to the right. – Turn the handlebar stub to the left. – Remove the throttle grip. 301449-10 – Push back protective cover  – Unscrew lock nut  – Screw adjusting screw all the way in.
  • Page 38 02/HANDLEBAR, CONTROLS AND INSTRUMENTS Throttle grip with code 5209: – Check that angle piece of the throttle cable (closer) is seated correctly.  Guideline Distance 9… 11 mm (0.35… 0.43 in)  » If the specified value is not reached: –...

  • Page 39: Adjusting The Throttle Cable At The Throttle Valve

    02/HANDLEBAR, CONTROLS AND INSTRUMENTS – Align the handlebar stub. – Position the distance sleeves. – Mount screw but do not tighten them yet.  – Tighten screw  Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) – Tighten screw ...
  • Page 40 Mount barrel adjuster  – Mount lock nuts but do not tighten them yet.  – Connect the KTM diagnostics tool. – Select the model. – Select "ECU Diagnosis". – Mark the "Engine management EFI LC8 RC8" control unit. –...
  • Page 41 02/HANDLEBAR, CONTROLS AND INSTRUMENTS – Ensure that rubber grommets are seated correctly.  – Install the air filter. ( p. 67) – Install the fuel tank. ( p. 71) 301460-10...

  • Page 42: 03/Frame

    03/FRAME Side stand switch Installation location – The side stand switch is fitted to the side stand. Side stand switch, connector AR ( p. 394) pin assignment Side stand signal Retracted "SSTAND SW" Side stand signal Extended "SSTAND SW" Side stand voltage "Side stand AD" 900040-60 Retracted 1.5…...

  • Page 43: Rear Frame Position

    03/FRAME – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( p. 192) – Adjust the foot brake pedal. ( p. 100) 100702-01 Rear frame position The frame rear height can be set to two different positions, enabling ergonomic adjust- ment of the seat height.
  • Page 44 03/FRAME – Remove screw with washer on the left and right sides of the vehicle.  – Push the rear end up until the drill holes of the frame are level with the lower rear drill holes of the rear. –...
  • Page 45 03/FRAME – When you screw in the rear left fixing screw, the plug-in cable binder is pushed  out of the thread. To reposition the cable of the lambda sensor, fix the plug-in cable binder in the remaining free drill hole. Info Check the cable routing.

  • Page 46: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM Adjusting the low-speed compression damping of the shock absorber Danger 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. Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. –...

  • Page 47: Adjusting The Rebound Damping Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Danger 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. – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 48: Adjusting The Vehicle Level At The Rear

    04/SHOCK ABSORBER, SWINGARM – Tighten screw  Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) 100689-11 Adjusting the vehicle level at the rear 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.

  • Page 49: Installing The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Remove screw  – Remove upper screw of the shock absorber.  – Remove nut . Pull out the pin of bell crank on the frame. Remove the bell   crank. 200603-10 – Remove the shock absorber toward the rear right. 200604-01 Installing the shock absorber –...

  • Page 50: Servicing The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Servicing the shock absorber Condition The shock absorber has been removed. – Remove the spring. ( p. 48) – Disassemble the damper. ( p. 49) – Disassemble the piston rod. ( p. 50) – Check the damper. ( p.

  • Page 51: Disassembling The Damper

    04/SHOCK ABSORBER, SWINGARM Disassembling the damper 8.10 – Remove the spring. ( p. 48) – Determine and note down the current setting of the rebound and compression damping. – Completely open the adjusting elements of the rebound and compression damping. –...

  • Page 52: Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Remove compression damping adjuster . Remove the spring, sleeve and piston.  200569-10 Disassembling the piston rod 8.11 – Disassemble the damper. ( p. 49) – Clamp the piston rod into a vise with the heim joint. –...

  • Page 53: Checking The Damper

    04/SHOCK ABSORBER, SWINGARM – Remove seal ring retainer  200573-10 – Remove locking cap and rubber buffer   200574-10 Checking the damper 8.12 Condition The damper has been disassembled. – Measure the inside diameter at both ends and in the middle of the damper car- tridge.

  • Page 54: Assembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Check the heim joint for damage and wear. » If there is damage or wear: – Change the heim joint. 300460-01 Assembling the piston rod 8.13 – Clamp the piston rod into a vise with the heim joint. –...

  • Page 55: Assembling The Damper

    04/SHOCK ABSORBER, SWINGARM – Mount rebound shim stack with the smaller shims at the top.  – Mount supporting plate  200571-11 – Mount and tighten nut  Guideline Nut, piston rod 30 Nm (22.1 lbf ft) 200570-11 Assembling the damper 8.14 –...
  • Page 56 04/SHOCK ABSORBER, SWINGARM – Fill the damper cartridge about half full. Shock absorber oil (SAE 2.5) (50180342S1) ( p. 437) 200587-01 – Lubricate O-ring of the seal ring retainer.  Lubricant (T158) ( p. 438) – Carefully mount the piston rod. 200568-11 –...

  • Page 57: Bleeding And Filling The Damper

    04/SHOCK ABSORBER, SWINGARM – Turn adjusting screw clockwise as far as it will go using an open end wrench.  – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport...
  • Page 58 04/SHOCK ABSORBER, SWINGARM – Position the control lever as shown in the photo. Control lever External tank is set to Closed, Damper is set to Vacuum and   Oil reservoir is set to Vacuum.  – Activate On/Off switch ...
  • Page 59 04/SHOCK ABSORBER, SWINGARM – When the vacuum gauge reaches the required value, turn control lever Oil reser- voir to Equalize Pressure.  Guideline 8 mbar The pressure gauge drops to the required value. 0 bar 200267-10 – When the pressure gauge reaches the required value, turn control lever Damper ...

  • Page 60: Filling The Damper With Nitrogen

    04/SHOCK ABSORBER, SWINGARM – Remove adapter from connector of the vacuum pump.   Info Hold the damper so that the filling port is at the highest location. – Remove the adapter. – Mount and tighten screw  Guideline Screw, filling port M10x1 14 Nm (10.3 lbf ft)

  • Page 61: Installing The Spring

    04/SHOCK ABSORBER, SWINGARM Installing the spring 8.17 – Clamp the damper into the vice with soft jaws. – Measure the overall spring length without a load. – Position the spring. Guideline Spring rate Medium (standard) 95 N/mm (542 lb/in) – Mount spring retainer ...

  • Page 62: Installing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM – Clamp the shock absorber into the vice with soft jaws. – Remove collar bushing of the heim joint with a drift.  – Turn the shock absorber around and remove collar bushing of the heim joint with ...
  • Page 63 04/SHOCK ABSORBER, SWINGARM – Mount lock rings on both sides.  200579-11 – Mount and grease seal rings on both sides.  Lubricant (T158) ( p. 438) 200578-11 – Push in both collar bushings of the heim joint.  200582-10...

  • Page 64: 05/Exhaust

    05/EXHAUST Lambda sensor Installation location – The lambda sensor for cylinder 1 is installed in the rear exhaust manifold.  – The lambda sensor for cylinder 2 is installed in the front exhaust manifold.  900007-61 Component description – In principle, the lambda sensor consists of a ceramic body that is coated with a ...

  • Page 65: Removing The Exhaust Cover Completely

    05/EXHAUST 11.7… 14.3 Ω Resistance at: 20 °C (68 °F) Removing the exhaust cover completely – Remove the side covers. ( p. 75) – Remove screws  – Remove screws on both sides.  – Take off exhaust cover completely. ...
  • Page 66 05/EXHAUST – Unplug connector of the lambda sensor (2nd cylinder). Open the cable binder.  200513-10 – Unplug connector of the lambda sensor (1st cylinder).  200514-10 – Remove screw . Slide the clamp upward.  200515-10 – Remove screw .

  • Page 67: Installing The Exhaust System

    05/EXHAUST – Remove nuts . Remove the manifold at the front with the seals.  200518-10 – Remove nuts . Remove the manifold at the rear with the seals.  200519-10 Installing the exhaust system Info The radiator has only been removed to illustrate the procedure more clearly. –...
  • Page 68 05/EXHAUST – Position the main silencer. Mount and tighten screws with the washers.  Guideline Remaining chassis screws 25 Nm (18.4 lbf ft) 0 0 3 0 0 3 0 0 3 200517-02 – Position the clamp. Mount and tighten screw ...

  • Page 69: 06/Air Filter

    06/AIR FILTER Removing the air filter 10.1 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. –...

  • Page 70: Installing The Filter Box Bottom

    06/AIR FILTER – Remove screws . Take off the retaining plates and holding brackets.  – Remove screw . Remove the cover.  200499-10 – Loosen hose clamps  200500-10 – Loosen the spring-loaded band-type clamp using the special tool. Pull off the ...
  • Page 71 06/AIR FILTER – Mount rubber sleeves . Position and tighten the lower hose clamps.  Guideline Hose clip, intake flange 1.5 Nm (1.11 lbf ft) 200502-11 – Detach the throttle valve body from the handlebar. Mount connector with the  seal.

  • Page 72: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM Removing the seat 11.1 – Insert the ignition key in the seat lock and turn it clockwise.  – Raise the rear of the seat, push it towards the rear, and remove it upwards. 100669-10 Fitting the seat 11.2 –...

  • Page 73: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 74: Removing The Fuel Tank Guard

    07/FUEL TANK, SEAT, TRIM 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 75: Installing The Fuel Tank Guard

    07/FUEL TANK, SEAT, TRIM – Remove screw  – Take off the fuel tank guard. 500246-10 Installing the fuel tank guard 11.8 Info The operations are the same on the left and right sides. – Position the fuel tank guard. –...

  • Page 76: Checking The Fuel Pressure During The Actuator Test

    07/FUEL TANK, SEAT, TRIM Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. – Remove the special tool. –...

  • Page 77: 08/Mask, Fender, Decal

    08/MASK, FENDER, DECAL Removing the side covers 12.1 – Remove screws on both sides.  – Remove side covers on both sides.  Info Watch out for the projections on the inside cover. 200492-10 Installing the side covers 12.2 – Position side covers on both sides.

  • Page 78: Installing The Inside Cover

    08/MASK, FENDER, DECAL – Remove screw  – Remove the screws of the EFI control unit . Unplug and remove the EFI control  unit. – Unplug the control unit of the electric starter lock  – Remove the overflow hose. Take off the right inside cover. 200495-12 Installing the inside cover 12.4...

  • Page 79: 09/Front Wheel

    09/FRONT WHEEL Removing the front wheel 13.1 – Jack up the motorcycle at the rear. ( p. 13) – Jack up the motorcycle at the front. ( p. 10) – Remove the screws from both brake calipers.  – Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc.

  • Page 80: Checking The Tire Condition

    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 81: Checking The Tire Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufac- ture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years. »...

  • Page 82: Checking The Front Brake Discs

    09/FRONT WHEEL Checking the front brake discs 13.5 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the brake disc in several places to see if it is within the specified wear tolerance ...

  • Page 83: 10/Rear Wheel

    10/REAR WHEEL Removing the rear wheel 14.1 – Jack up the motorcycle at the rear. ( p. 13) – Remove nut  – Remove chain adjuster  – Remove the axle  100722-10 – Push the rear wheel as far forward as possible and then remove the chain from the rear sprocket.

  • Page 84: Installing The Rear Wheel - When Installing The Engine

    10/REAR WHEEL – Push the rear wheel as far forward as possible and place the chain on the rear sprocket. – Pull the rear wheel back and insert the axle. 100726-01 – Place the chain adjuster on the tensioning screw. ...

  • Page 85: Checking The Rear Brake Disc

    10/REAR WHEEL – Push the rear wheel forward as far as possible and place the chain on the rear sprocket. – Pull the rear wheel back and push in the wheel spindle. 100726-01 – Place chain adjuster on the tensioning screw. ...

  • Page 86: Cleaning The Chain

    10/REAR WHEEL Cleaning the chain 14.6 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 87: Adjusting The Chain Tension

    10/REAR WHEEL Adjusting the chain tension 14.8 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may snap or the countershaft of the transmission can break.

  • Page 88: Checking Chain Wear

    10/REAR WHEEL Checking chain wear 14.10 – 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. ...
  • Page 89 10/REAR WHEEL – Install the rear wheel. ( p. 81)

  • Page 90: 11/Wiring Harness, Battery

    11/WIRING HARNESS, BATTERY Electric starter lock control unit 15.1 Installation location – The electric starter lock control unit is located behind the right-hand side cover. Electric starter lock control unit, connector DO ( p. 399) pin assignment 900013-01 Description of function 900015-10 –...

  • Page 91: Installing The Battery

    11/WIRING HARNESS, BATTERY – Disconnect negative (minus) cable of the battery.  100734-10 – Remove the cover of the positive terminal. – Disconnect the positive (plus) cable of the battery.  100735-10 – Remove screws  – Removing the securing bracket ...

  • Page 92: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 93: Changing The Main Fuse

    11/WIRING HARNESS, BATTERY Changing the main fuse 15.6 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. –...
  • Page 94 11/WIRING HARNESS, BATTERY – Check the fuses. Info A defective fuse can be identified by the burned-out fuse wire  – Remove the faulty fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system (optional) 100741-10 Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp Fuse 3 - 10A - horn, brake light Fuse 4 - 10A - radiator fan Fuse 5 - 10A - fuel pump...

  • Page 95: 13/Brake System

    13/BRAKE SYSTEM Brake linings 16.1 The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the brake linings are entered in the homologation documents. Info Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 96 13/BRAKE SYSTEM Info Never user DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces. Use only clean brake fluid from a sealed container! –...

  • Page 97: Checking The Front Brake Fluid Level

    13/BRAKE SYSTEM – Position the brake caliper. Mount the screws but do not tighten them yet. – Repeat the operation on the opposite side. – Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point. Fix the hand brake lever in the acti- vated position.

  • Page 98: Adjusting The Basic Position Of The Hand Brake Lever

    13/BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never user DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 99: Changing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 100 13/BRAKE SYSTEM – Remove locking clip  301492-10 – Remove bolt  301493-10 – Remove brake linings  – Remove spring  – Clean the brake caliper. 301494-10 – Position brake linings and spring   – Mount bolt  301495-10 –...

  • Page 101: Checking The Rear Brake Fluid Level

    13/BRAKE SYSTEM – Refit screw with membrane. Info Clean up overflowed or spilt brake fluid immediately with water. Checking the rear brake fluid level 16.9 Warning Danger of accidents Failure of the brake system. – 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.

  • Page 102: Adjusting The Foot Brake Pedal Stub

    13/BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cover with membrane   – Add brake fluid to the MAX level. Brake fluid DOT 4 / DOT 5.1 ( p. 436) – Refit screw with membrane. Info Clean up overflowed or spilt brake fluid immediately with water. 100717-10 Adjusting the foot brake pedal stub 16.11...

  • Page 103: Removing The Rear Brake System

    13/BRAKE SYSTEM Removing the rear brake system 16.13 – Remove the rear wheel. ( p. 81) – Unplug the brake light switch. Remove the cable clip. – Remove screw  – Remove screws . Take off the footrest bracket.  200525-10 –...

  • Page 104: 14/Light System, Instruments

    14/LIGHT SYSTEM, INSTRUMENTS Immobilizer control unit 17.1 Installation location – The ICU is located under the ignition lock. Imobilizer control unit, connector DN ( p. 399) pin assignment Imobilizer control unit, antenna coil, connector DV ( p. 401) pin assignment Description of function The purpose of the imobilizer control unit is to protect against unauthorized persons using the vehicle.
  • Page 105 14/LIGHT SYSTEM, INSTRUMENTS – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON posi- tion EFI warning lamp (MIL) lights up, switches off, and then starts to flash. The immobilizer indicator lamp lights up, switches off briefly, and flashes according to the number of functioning black ignition keys includ-...

  • Page 106: Activating The Icu

    14/LIGHT SYSTEM, INSTRUMENTS – Switch off the ignition by turning the black programming key to the position OFF – Remove the black ignition key. – To activate further ignition keys, repeat the last 4 steps with the respective ignition key. –...

  • Page 107: Combination Instrument - Activation Of The Bootloader Mode

    14/LIGHT SYSTEM, INSTRUMENTS – Press "Continue". – Read the information page in the KTM diagnostics tool then using "Continue" pro- gramm the ICU. – Switch off the ignition by turning the black programming key to the position OFF – Switch on the ignition by turning the black programming key to the position ON –...

  • Page 108: Setting Road Or Race Mode

    14/LIGHT SYSTEM, INSTRUMENTS Setting ROAD or RACE mode 17.6 Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the MODE button briefly. The mode set is shown in the info display. –...

  • Page 109: Setting The Blank Time Of The Lap Button Lap Blank T

    14/LIGHT SYSTEM, INSTRUMENTS – Set the engine speed with the button or the button – Press the MODE button briefly. The settings are stored and the display changes to the SETTING menu. Info At delivery, RPM1 is set to 10000 and RPM2 to 10500. –...

  • Page 110: Setting The Fuel Reserve Display Tripf Reset

    14/LIGHT SYSTEM, INSTRUMENTS Info When delivered, the number of TOTAL LAPS is set to 99 laps. – Set the number of laps with the button or the button. Info You can set TOTAL LAPS to between 1 and 99 laps. –...

  • Page 111: Setting The Temperature Unit Set °C/°F

    14/LIGHT SYSTEM, INSTRUMENTS – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. – Press the MODE button briefly. – Press the MODE button briefly. The selected unit appears on the left of the display.

  • Page 112: Resetting Service Display

    14/LIGHT SYSTEM, INSTRUMENTS – Press the MODE button briefly. Resetting service display 17.15 Condition The ignition is on. The motorcycle is stationary. – Press the button and button for 3-5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.

  • Page 113: Adjust The Headlight Range

    14/LIGHT SYSTEM, INSTRUMENTS Adjust the headlight range 17.17 – Check the headlight setting. ( p. 110) – Adjust the beam distance of the headlight by turning screw  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 114: Changing The Low Beam Bulb

    14/LIGHT SYSTEM, INSTRUMENTS – Position the lug of the lamp cover in the notch. Engage the latch.  – Check that the lighting is functioning properly. 400422-12 – Position the cover. Info Check for correct positioning and freedom of movement of the brake lines. –...

  • Page 115: Changing The High Beam Bulb

    14/LIGHT SYSTEM, INSTRUMENTS – Disconnect plug-in connector  – Push off the retaining clamp on both sides, squeeze and fold to the side.  – Remove headlight bulb  700295-01 – Position the new headlight bulb in the headlight housing. Low beam / high beam (H7 / base PX26d) ( p.
  • Page 116 14/LIGHT SYSTEM, INSTRUMENTS – Remove screws . Remove the cover.  100745-10 – Release the latch  – Remove the lamp cover  100746-10 – Disconnect plug-in connector  – Push off the retaining clamp on both sides, squeeze and fold to the side. ...

  • Page 117: 30/Engine

    30/ENGINE Removing the engine 18.1 – Jack up the motorcycle at the rear. ( p. 13) – Dismount the fuel tank. ( p. 70) – Remove the inside cover. ( p. 75) – Remove the air filter. ( p. 67) –...
  • Page 118 30/ENGINE – Remove screws . Remove the slave cylinder with the spacer and sleeves.  – Remove screws . Take off the engine sprocket cover.  200521-10 – Shift into first gear. Info The purpose is to loosen the nut of the engine sprocket. –...

  • Page 119: Preparing The Engine For Installation

    30/ENGINE – Remove nut . Pull out the pin of the bell crank on the frame.  – Remove the nut of the swingarm pivot. Pull out the swingarm pivot. – Take off the swingarm with the shock absorber. 200529-10 –...
  • Page 120 30/ENGINE – Position the swingarm with the shock absorber. Info Do not forget the chain. – Center the swingarm. Centering pin (61229051000) ( p. 446) – Mount the swingarm pivot. Mount and tighten the nut. Guideline 200529-01 Nut, swingarm pivot M19x1.5 130 Nm Thread greased...
  • Page 121 30/ENGINE – Position the footrest bracket. Mount and tighten screws  Guideline Screw, front footrest 25 Nm Loctite ® 243™ bracket (18.4 lbf ft) – Position the shift shaft deflection. Mount and tighten screw with the washers.  Guideline Screw, shift shaft deflector 18 Nm Loctite ®...

  • Page 122: Setting The Engine To Ignition Top Dead Center Of The Rear Cylinder

    Fill up with engine oil. ( p. 212) – Take a short test ride. – Read out the trouble code memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p. 209) –...

  • Page 123: Setting The Engine To Ignition Top Dead Center Of The Front Cylinder

    30/ENGINE – Turn the crankshaft counterclockwise until markings are flush with the edge of  the cylinder head. 301441-10 – Remove screw  – Look through the hole to check that the position notch of the crankshaft is visible. – Screw in special tool ...

  • Page 124: 30/Disassembling The Engine

    30/DISASSEMBLING THE ENGINE Clamping the engine into the engine work stand 19.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 443) Engine holder (61229002000) ( p. 443) – Mount the engine on special tool ...

  • Page 125: Removing The Front Valve Cover

    30/DISASSEMBLING THE ENGINE Removing the front valve cover 19.4 – Remove ignition coil  – Remove screws . Take off the valve cover with the valve cover seal.  – Remove the spark plug using the special tool. Spark plug wrench (75029172000) ( p.

  • Page 126: Removing The Starter Motor

    30/DISASSEMBLING THE ENGINE Removing the starter motor 19.7 – Remove screw . Take off the starter motor.  301348-10 Removing the oil filler tube 19.8 – Remove screws  – Remove the oil filler tube with the O-ring. 301349-10 Removing the heat exchanger 19.9 –...

  • Page 127: Removing The Rear Camshaft

    30/DISASSEMBLING THE ENGINE Removing the rear camshaft 19.11 – Remove spark plug shaft insert  – Loosen and remove screws from the outside to the inside.  Info The cams should not activate the valves. – Remove the camshaft bearing bridge. 301352-10 –...

  • Page 128: Setting The Engine To Ignition Top Dead Center Of The Front Cylinder

    30/DISASSEMBLING THE ENGINE Setting the engine to ignition top dead center of the front cylinder 19.14 – Loosen special tool by several turns.  Engine blocking screw (61229015000) ( p. 444) – Keep the timing chain tensioned. – Continue turning the crankshaft counterclockwise until markings of the front ...

  • Page 129: Removing The Front Piston

    30/DISASSEMBLING THE ENGINE Removing the front piston 19.18 – Push the cylinder up. Info Push the cylinder up until the piston pin can be removed. Make sure that the two pins remain in place. 301363-10 – Remove piston pin retainer ...

  • Page 130: Removing The Torque Limiter And Idler

    30/DISASSEMBLING THE ENGINE Removing the torque limiter and idler 19.21 – Take off torque limiter  – Remove idler with the washers and needle bearing.  Info The idler has one disk at the front and one at the rear; the front washer usu- ally sticks to the generator cover.

  • Page 131: Removing The Oil Filter

    30/DISASSEMBLING THE ENGINE – Remove the timing chain, needle bearing and the washer lying behind it.  Info If the timing chain is to be used again, note the direction of travel and the cylinder on which it was used. 200354-10 Removing the oil filter 19.24...

  • Page 132: Removing The Gear Position Sensor

    30/DISASSEMBLING THE ENGINE Removing the gear position sensor 19.27 – Remove the screws. Remove gear position sensor with the O-ring.  301398-10 – Remove contact pin and the contact spring.  301399-10 Removing the left suction pump 19.28 – Remove screws ...

  • Page 133: Removing The Water Pump Wheel

    30/DISASSEMBLING THE ENGINE – Remove external rotor and internal rotor   – Remove pin  301402-10 Removing the water pump wheel 19.29 – Remove screws  – Take off the water pump cover. 301394-10 – Remove dowels  – Remove screw .

  • Page 134: Removing The Idler And Timing Chain On The Right

    30/DISASSEMBLING THE ENGINE – Take off dowels . Remove the clutch cover seal.  – Remove check valve  200401-10 Removing the idler and timing chain on the right 19.31 – Remove idler  – Take off the timing chain. Info If the timing chain is to be used again, note the direction of travel and the cylinder on which it was used.

  • Page 135: Removing The Primary Gear

    30/DISASSEMBLING THE ENGINE – Remove outer clutch hub with washer   301403-10 – Remove needle bearing and washer   301404-10 Removing the primary gear 19.34 – Loosen nut of primary gear and remove it together with the washer. ...

  • Page 136: Removing The Shift Shaft

    30/DISASSEMBLING THE ENGINE – Remove pin and washer   – Remove screws  – Remove the oil pump cover. 301411-10 – Remove external rotor and internal rotor   – Remove pin  301412-10 Removing the shift shaft 19.36 –...

  • Page 137: Removing The Locking Lever

    30/DISASSEMBLING THE ENGINE Removing the locking lever 19.38 – Remove screw  – Take off locking lever with the sleeve and spring.  301415-10 Removing the left engine case 19.39 200421-10 – Remove screws   – Swing the left section of the engine case upward. Remove screw ...

  • Page 138: Removing The Middle Suction Pump

    30/DISASSEMBLING THE ENGINE Removing the middle suction pump 19.41 – Take off oil pump shaft with internal rotor   200425-10 – Remove internal rotor and pin from the oil pump shaft    – Remove external rotor  200426-10 Removing the transmission shaft 19.42...

  • Page 139: Removing The Oil Spray Tube

    30/DISASSEMBLING THE ENGINE – Place the engine in an upright position. – Remove lock ring and the stop disk.  200430-10 – Pull both transmission shafts out of the bearing seats together. 200431-10 Removing the oil spray tube 19.43 – Remove oil spray tube .

  • Page 140: 30/Engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 20.1 – Remove studs  200442-10 – Remove jet  – Remove oil jets  200440-10 – Remove bearing retainers  – Remove the dowels. –...

  • Page 141: Removing The Main Bearing Of The Right Engine Case Section

    30/ENGINE - WORK ON INDIVIDUAL PARTS Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed. – Mount and tighten bearing retainers ...

  • Page 142: Selecting The Main Bearing Shells

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Place the engine case section on special tool  Press sleeve (61229045000) ( p. 446) – Place special tool with the smaller diameter on the bearing shells and press from  the inside to the outside. Press drift/press sleeve (61229044000) ( p.

  • Page 143: Work On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Position bearing shell bracket . Mount and tighten the screws.  Guideline Screw, bearing retainer 6 Nm Loctite ® 243™ (4.4 lbf ft) 200435-11 Work on the left section of the engine case 20.5 –...
  • Page 144 30/ENGINE - WORK ON INDIVIDUAL PARTS Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in. –...

  • Page 145: Removing The Left Main Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the left main bearing 20.6 – Remove the screws and take off bearing shell bracket  200443-10 – Mark joint of the main bearing shells as shown in the figure.  200444-10 – Place the engine case section on special tool ...

  • Page 146: Changing The Conrod Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Position bearing shell bracket . Mount and tighten the screws.  Guideline Screw, bearing retainer 6 Nm Loctite ® 243™ (4.4 lbf ft) 200443-11 Changing the conrod bearing 20.8 Info Perform the operation on both connecting rods. –...

  • Page 147: Work On The Clutch Cover

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Oil the bearing shells. – Position the connecting rod bearing cap according to the markings made when they were disassembled. Mount the new connecting rod screws and tighten them using the special tool. Guideline Screw, conrod bearing M10x1...

  • Page 148: Changing The Step Bearing Of The Crankshaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Press in outer shaft seal ring fully, with the open side flush and facing outwards.  – Insert water pump cover  200456-10 Changing the step bearing of the crankshaft 20.10 – Mark the position of the bearing joint ...

  • Page 149: Checking The Radial Clearance Of The Bottom Connecting Rod Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the radial clearance of the bottom connecting rod bearing 20.11 Info Perform the operation on both connecting rods. – Position the bearing shells. Insert the Plastigauge measuring strips offset by 90°  from the bearing joint. Plastigauge measuring strips (60029012000) ( p.

  • Page 150: Checking/Measuring The Piston

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 441) ≤ 0.05 mm (≤ 0.002 in) Cylinder/cylinder head - sealing area distortion »...

  • Page 151: Checking The Piston Ring End Gap

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Piston size is marked on the piston head.  301419-10 Checking the piston ring end gap 20.14 – Remove the piston ring from the piston. – Place the piston ring in the cylinder and align it with the piston. Guideline Under the upper edge of the cylinder 10 mm (0.39 in)
  • Page 152 30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove plugs with the O-ring.  – Pull out cam lever axle with a suitable M5 screw and remove the cam lever.  200467-10 – Remove shims and label the installation position.  200468-10 –...
  • Page 153 30/ENGINE - WORK ON INDIVIDUAL PARTS – Tension the valve spring with a special tool. Valve spring mounter (59029019000) ( p. 440) Valve spring mounting device (78029060000) ( p. 448) – Mount valve keys . Release the tension on the valve spring. ...

  • Page 154: Checking The Cylinder Head

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Mount screw  Guideline Plug, vacuum connection 5 Nm Loctite ® 243™ (3.7 lbf ft) – Mount vacuum connection  Guideline Vacuum connection 5 Nm Loctite ® 243™ (3.7 lbf ft) – Mount and grease O-rings ...

  • Page 155: Work On The Right Idler

    30/ENGINE - WORK ON INDIVIDUAL PARTS » If the measured value does not equal the specified value: – Change the valve. – Check the valve stem diameter. Valve - valve stem diameter Exhaust 5.893… 5.970 mm (0.23201… 0.23504 in) Intake 5.965…...

  • Page 156: Checking The Timing Assembly

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the timing assembly 20.19 – Clean all parts well. 0 0 2 – Check idler for damage and wear.  » If there is damage or wear: – Change the idler. – Check timing chain tensioning rail for damage and wear.

  • Page 157: Checking The Oil Pressure Regulator Valve

    30/ENGINE - WORK ON INDIVIDUAL PARTS Info This position is necessary for installation. If the timing chain tensioner is now pressed in once more (while it is installed) and then pulled out no more than halfway (preventing it from coming out fully), the latching system locks and the timing chain tensioner can no longer be compacted;...

  • Page 158: Checking The Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the clutch 20.23 0 0 4 0 0 3 0 0 8 0 0 5 0 0 9 0 0 7 0 0 6 0 0 b o 0 0 1 0 0 2 301421-01 –...

  • Page 159: Checking The Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Change all intermediate clutch discs. – Check the thickness of intermediate clutch discs  Intermediate disk - thickness New condition 1.95… 2.05 mm (0.0768… 0.0807 in) Wear limit 1.85 mm (0.0728 in) » If the intermediate clutch discs do not meet specifications: –...

  • Page 160: Preassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Change the shift drum. – Check springs of the shift rails for damage and wear.  » If the spring is broken or worn: – Change the spring of the shift rail. – Check the shift rails on a flat surface for run-out.

  • Page 161: Dismantling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove stop disk and second-gear fixed gear   – Remove the sixth-gear idler gear  – Remove needle bearing and stop disk   – Remove the third/fourth-gear sliding gear  – Remove lock ring ...

  • Page 162: Checking The Transmission

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the transmission 20.28 0 0 2 0 0 1 0 0 4 0 0 4 0 0 6 0 0 6 0 0 7 0 0 5 0 0 1 0 0 5 0 0 6 0 0 8 0 0 4...

  • Page 163: Assembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Change the needle bearing. Assembling the main shaft 20.29 Info Use new lock rings and new stop disks with every repair. – Oil all parts carefully before assembling. – Check the transmission. ( p.
  • Page 164 30/ENGINE - WORK ON INDIVIDUAL PARTS 0 0 b r 0 0 b q 0 0 b p 0 0 b o 0 0 b s 0 0 b n 0 0 b l 0 0 b m 0 0 9 0 0 8 0 0 b k 0 0 7...

  • Page 165: 30/Assembling The Engine

    30/ASSEMBLING THE ENGINE Installing the timing chain rails of the left engine case section 21.1 – Position timing chain guide rail . Mount and tighten screw   Guideline Screw, timing chain guide 15 Nm Loctite ® 243™ rail (11.1 lbf ft) Info Ensure that there is no thread locking material at the collar of the screw;...

  • Page 166: Installing The Oil Spray Tube

    30/ASSEMBLING THE ENGINE Installing the oil spray tube 21.3 – Mount new O-rings on oil spray tube   – Mount the oil spray tube. must engage in recess   200433-01 Installing the transmission shaft 21.4 – Clamp the right section of the engine case. Engine work stand (61229001000) ( p.

  • Page 167: Installing The Middle Suction Pump

    30/ASSEMBLING THE ENGINE – Swing shift forks to one side.  Info Watch out for the shift rollers  – Insert shift drum into the bearing seat.  – Let the shift forks engage in the shift grooves. 200428-11 – Mount shift rails with the pressure springs.

  • Page 168: Installing The Left Engine Case

    30/ASSEMBLING THE ENGINE Installing the left engine case 21.7 – Mount dowels  – Mount gasket  – Check that dowel is correctly seated.  301422-11 – Degrease the sealing area and coat thinly with sealant. Loctite ® 5910 Info Only coat the sealing area around the outside (see figure).

  • Page 169: Installing The Locking Lever

    30/ASSEMBLING THE ENGINE Info Screws must always be replaced with new screws.  – Mount screw  Installing the locking lever 21.8 – Position locking lever with sleeve and spring    – Mount and tighten screw  Guideline Screw, locking lever 10 Nm Loctite...

  • Page 170: Installing The Force Pump

    30/ASSEMBLING THE ENGINE Installing the force pump 21.11 – Mount pin  Info Ensure that pins are seated correctly.  – Mount internal rotor and external rotor   Marking of the internal rotor is visible after mounting while that of the exter- ...

  • Page 171: Installing The Left Suction Pump

    30/ASSEMBLING THE ENGINE Installing the left suction pump 21.12 – Mount pin  – Mount internal rotor and external rotor   Marking of the internal rotor is visible after mounting while that of the exter-  nal rotor is not. –...

  • Page 172: Installing The Primary Gear

    30/ASSEMBLING THE ENGINE Installing the primary gear 21.14 – Ensure that the spring washer is seated properly. – Mount primary gear  – Mount the washer and nut and tighten the nut.  Guideline Nut, primary gear M33LHx1.5 130 Nm Loctite ®...

  • Page 173: Installing The Clutch Facing

    30/ASSEMBLING THE ENGINE – Insert special tool  Clutch holder (61229003000) ( p. 443) – Mount the washer and nut and tighten the nut.  Guideline Nut, inner clutch hub M22x1.5 130 Nm Loctite ® 243™ (95.9 lbf ft) 200408-11 Installing the clutch facing 21.16 –...

  • Page 174: Installing The Idler And Timing Chain On The Right

    30/ASSEMBLING THE ENGINE Installing the idler and timing chain on the right 21.17 – Position timing chain according to the direction of travel.  – Place the timing chain over the toothing of idler . Align markings    –...

  • Page 175: Installing The Water Pump Wheel

    30/ASSEMBLING THE ENGINE Installing the water pump wheel 21.19 – Mount the washer and water pump wheel. – Mount and tighten screw  Guideline Screw, water pump wheel 10 Nm Loctite ® 243™ (7.4 lbf ft) – Mount dowels  –...

  • Page 176: Installing The Balancer Shaft

    30/ASSEMBLING THE ENGINE Installing the balancer shaft 21.22 – Mount the rear washer and needle bearing. – Mount balancer shaft  Markings are aligned.   – Mount washer  200357-10 Installing the idler and timing chain on the left 21.23 –...

  • Page 177: Installing The Oil Filter

    30/ASSEMBLING THE ENGINE Installing the oil filter 21.24 – Tilt the engine sideways and fill the oil filter housing to about ⅓ full with engine oil. – Insert oil filter  – Lubricate the O-ring of oil filter cover . Mount the oil filter cover. ...

  • Page 178: Installing The Torque Limiter And Idler

    30/ASSEMBLING THE ENGINE Installing the torque limiter and idler 21.26 – Mount the rear washer, needle bearing, idler and front washer.  – Mount torque limiter with the rear washer.  200347-11 Installing the ignition pulse generator 21.27 – Position the ignition pulse generator ...

  • Page 179: Installing The Rear Piston

    30/ASSEMBLING THE ENGINE Installing the rear piston 21.30 – Shift the joint of the piston rings by 120°. – Place the oiled piston on the cylinder. Tighten the piston rings using the special tool. Piston ring mounting tool (60029015000) ( p.

  • Page 180: Installing The Rear Cylinder Head

    30/ASSEMBLING THE ENGINE – Position the new piston pin retainer. Info For clarity, the following steps are illustrated using a disassembled piston. – Insert the special tool and firmly press it toward the piston. – Turn the special tool counterclockwise, thereby pressing the piston pin retainer into the groove.

  • Page 181: Installing The Rear Camshaft

    30/ASSEMBLING THE ENGINE Installing the rear camshaft 21.32 – Pull up the timing chain and insert intake camshaft  Info The intake camshaft is labeled with eh. – Place the timing chain over the rear sprocket of the intake camshaft. Marking is aligned.

  • Page 182: Setting The Engine To Ignition Top Dead Center Of The Front Cylinder

    30/ASSEMBLING THE ENGINE Setting the engine to ignition top dead center of the front cylinder 21.34 – Remove special tool  – Keep the timing chain tensioned. – Turn the crankshaft counterclockwise by the specified value. Guideline 1 turn 301382-10 –...
  • Page 183 30/ASSEMBLING THE ENGINE – Position the new cylinder base gasket  301383-10 – Ensure that piston marking faces the outfeed side.  301365-10 – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. 301374-10 –...

  • Page 184: Installing The Front Cylinder Head

    30/ASSEMBLING THE ENGINE – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the dowel pins engage. 301375-10 Installing the front cylinder head 21.36 – Mount the new cylinder head gasket. – Mount the cylinder head. Mount and tighten the new cylinder head screws ...

  • Page 185: Installing The Front Timing Chain Tensioner

    30/ASSEMBLING THE ENGINE – Thoroughly clean all oil jets and blow them out with compressed air. – Position the camshaft bearing bridge. – Mount screws and tighten them from the outside to the inside.  Guideline Screw, camshaft bearing support 10 Nm (7.4 lbf ft) Screw, camshaft bearing support Step 1...

  • Page 186: Installing The Oil Filler Tube

    30/ASSEMBLING THE ENGINE Installing the oil filler tube 21.40 – Mount the oil filler tube with the O-ring. – Mount and tighten screws  Guideline Remaining engine screws 10 Nm (7.4 lbf ft) 301349-10 Installing the starter motor 21.41 – Grease O-ring .

  • Page 187: Checking The Rear Valve Clearance

    30/ASSEMBLING THE ENGINE – Turn the engine one crankshaft turn in a counterclockwise direction. Marking faces outward and is flush with the edge of the cylinder head.  – Remove screws  – Mount the new screws but do not tighten them yet. ...

  • Page 188: Adjusting The Rear Valve Clearance

    30/ASSEMBLING THE ENGINE – On all valves, check the valve clearance between the camshaft and cam lever. Guideline Valve clearance Exhaust at: 20 °C (68 °F) 0.25… 0.30 mm (0.0098… 0.0118 in) Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in) Feeler gauge (59029041100) ( p.

  • Page 189: Checking The Front Valve Clearance

    30/ASSEMBLING THE ENGINE – Turn the engine one crankshaft turn in a counterclockwise direction. Marking faces outward and is flush with the edge of the cylinder head.  – Remove screws  – Mount the new screws but do not tighten them yet. ...

  • Page 190: Adjusting The Front Valve Clearance

    30/ASSEMBLING THE ENGINE Adjusting the front valve clearance 21.49 – Remove the front timing chain tensioner. ( p. 126) – Remove the front camshafts. ( p. 126) – Swing up cam lever  – Remove shims and set them down according to the installation position. ...

  • Page 191: Mounting The Engine Bracket

    30/ASSEMBLING THE ENGINE – Mount ignition coil  Mounting the engine bracket 21.52 – Position the engine bracket. – Mount and tighten screws   Guideline Screw, engine console 20 Nm Loctite ® 243™ (14.8 lbf ft) 301345-10 – Position the engine bracket. –...

  • Page 192: 31/Secondary Air System

    31/SECONDARY AIR SYSTEM Exhaust air injection 22.1 Installation location – The exhaust air injection valve is located under the air filter box. Exhaust air injection valve, connector FE ( p. 403) pin assignment Function description – The exhaust air injection valve injects purified fresh air into the exhaust port to improve exhaust emissions as long as closed loop control is not yet active.

  • Page 193: 32/Clutch

    32/CLUTCH Checking fluid level of hydraulic clutch 23.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 194: 34/Shift Mechanism

    34/SHIFT MECHANISM Adjusting shift lever stub 24.1 – Remove the screw with the shift lever stub.  – Position the shift lever stub with the screw in one of the holes according to the  desired lever length. Guideline Standard Central hole –...

  • Page 195: Nm Loctite

    34/SHIFT MECHANISM – The shift rod can be mounted both on the shift lever variably at an upper or lower position, and on the reverse gear change of the shift shaft in two different posi- tions. Guideline 0 0 A Standard Shift lever: lower drill hole, ...

  • Page 196: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM Checking the coolant level 25.1 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the engine and cooling system cool down first.

  • Page 197: Removing The Radiator

    35/WATER PUMP, COOLING SYSTEM Removing the radiator 25.3 – Remove the exhaust cover completely. ( p. 63) – Remove the inside cover. ( p. 75) – Remove the drain plug of water pump and of radiator . Completely drain the ...

  • Page 198: Adding Coolant/Bleeding The Cooling System

    35/WATER PUMP, COOLING SYSTEM – Mount and tighten screw  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Mount the radiator hose. Position and tighten hose clamps  200506-11 – Mount radiator hoses . Position and tighten the hose clamps. ...

  • Page 199: Filling The Cooling System Compensating Tank

    35/WATER PUMP, COOLING SYSTEM – Completely fill the radiator with coolant and close it with radiator cap  – Position the vehicle on a level surface. – Remove the cap of the compensating tank. – Add coolant to the compensating tank until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX.

  • Page 200: 36/Cylinder Head

    36/CYLINDER HEAD Engine coolant temperature sensor cylinder 1 26.1 Installation location – The engine coolant temperature sensor for cylinder 1 is located on the left-hand side of the rear cylinder head. 900017-01 Component description – The engine coolant temperature sensor is a negative temperature coefficient ther- mistor (NTC resistor).

  • Page 201: Engine Coolant Temperature Sensor For Cylinder 2

    36/CYLINDER HEAD 100… 122 Ω Resistance at: 120 °C (248 °F) Engine coolant temperature sensor for cylinder 2 26.2 Installation location – The engine coolant temperature sensor for cylinder 2 is located on the right-hand side of the front cylinder head. 900018-01 Component description –...

  • Page 202: Checking The Valve Clearance

    36/CYLINDER HEAD 128… 156 Ω Resistance at: 110 °C (230 °F) 100… 122 Ω Resistance at: 120 °C (248 °F) Checking the valve clearance 26.3 – Remove the filter box bottom. ( p. 67) – Remove the side covers. ( p.

  • Page 203: Adjusting The Rear Valve Clearance

    36/CYLINDER HEAD – Remove special tool  – Crank the engine several times. Check the valve clearance and correct it if neces- sary. – Remove special tool and screw in and tighten screw   Guideline Plug, crankshaft retainer 15 Nm (11.1 lbf ft) 200540-10 –...

  • Page 204: Adjusting The Front Valve Clearance

    36/CYLINDER HEAD Adjusting the front valve clearance 26.5 – Remove the front camshafts. ( p. 206) – Raise cam lever on the outside.  – Remove shims and set them down according to the installation position.  – Correct and insert the shims as indicated by the results of the valve clearance check.

  • Page 205: Adjusting The Rear Cylinder Control Time

    36/CYLINDER HEAD Adjusting the rear cylinder control time 26.8 – Set the engine to ignition top dead center of the rear cylinder. ( p. 120) – Remove special tool  Engine blocking screw (61229015000) ( p. 444) Info For purposes of illustration, the following operations are shown with the engine deinstalled.

  • Page 206: Adjusting The Front Cylinder Control Time

    36/CYLINDER HEAD Adjusting the front cylinder control time 26.9 – Set the engine to ignition top dead center of the front cylinder. ( p. 121) – Remove special tool  Engine blocking screw (61229015000) ( p. 444) Info For purposes of illustration, the following operations are shown with the engine deinstalled.

  • Page 207: Removing The Rear Camshaft

    36/CYLINDER HEAD Removing the rear camshaft 26.10 Condition The engine is positioned at ignition top dead center of the rear cylinder – Remove screw with the O-ring.  – Pull out timing chain tensioner  200549-10 – Remove spark plug shaft insert ...

  • Page 208: Removing The Front Camshafts

    36/CYLINDER HEAD Removing the front camshafts 26.12 Condition The engine is positioned at ignition top dead center of the front cylinder – Remove screw with the O-ring.  – Pull out timing chain tensioner  200550-10 – Remove spark plug shaft insert ...

  • Page 209: Installing The Rear Timing Chain Tensioner

    36/CYLINDER HEAD Installing the rear timing chain tensioner 26.14 – Prepare the timing chain tensioner for installation. ( p. 154) – After it has been positioned in the installation location, insert timing chain ten- sioner with a new O-ring.  –...

  • Page 210: 38/Lubrication System

    38/LUBRICATION SYSTEM Oil circuit 27.1 400492-60 Oil circuit of middle suction pump Oil screen of oil drain plug in gearbox Middle suction pump Heat exchanger Oil exit in oil tank Oil circuit of left suction pump Crankcase Left suction pump Lubricating slots in gearbox Oil circuit of force pump Oil screen of oil drain plug in oil tank...

  • Page 211: Checking The Engine Oil Level

    38/LUBRICATION SYSTEM Checking the engine oil level 27.2 Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Remove oil dipstick . Check the engine oil level in the measurement range. ...

  • Page 212: (14.8 Lbf Ft)

    38/LUBRICATION SYSTEM – Remove screws  – Take off the left exhaust cover  100771-10 – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove oil drain plug with the magnet, O-rings and oil screen.

  • Page 213: Removing The Oil Filter

    38/LUBRICATION SYSTEM – Position the left exhaust cover  – Mount and tighten screws  Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) 100771-10 Removing the oil filter 27.5 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –...

  • Page 214: Installing The Oil Filter

    38/LUBRICATION SYSTEM Installing the oil filter 27.6 – Insert oil filter  – Lubricate the O-ring of the oil filter cover. Mount oil filter cover  – Mount and tighten the screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) 100776-10 Filling up with engine oil 27.7...

  • Page 215: Adding Engine Oil

    38/LUBRICATION SYSTEM Adding engine oil 27.8 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Check the engine oil level. ( p. 209) – Remove the dipstick and add engine oil.  Condition External temperature: ≥...
  • Page 216 38/LUBRICATION SYSTEM – Remove screws  – Take off the left exhaust cover  100771-10 – Place a suitable container under the engine. – Remove screws . Take off the oil filter cover with the O-ring.  – Remove oil filter ...

  • Page 217: Removing The Oil Jet For The Clutch Lubrication

    38/LUBRICATION SYSTEM Coolant temperature: ≥ 70 °C 1.3… 2.3 bar (19… 33 psi) (≥ 158 °F) Engine speed: 1,500 rpm Coolant temperature: ≥ 70 °C 3.0… 4.0 bar (44… 58 psi) (≥ 158 °F) Engine speed: 5,000 rpm » The specifications have not been met: –...

  • Page 218: Checking / Cleaning The Oil Jet For Clutch Lubrication

    38/LUBRICATION SYSTEM – Remove plug  301427-10 – Remove oil jet  301429-11 Checking / cleaning the oil jet for clutch lubrication 27.11 – Remove the oil jet for the clutch lubrication. ( p. 215) – Check the oil jet for clutch lubrication is not blocked. »...
  • Page 219 38/LUBRICATION SYSTEM – Position the engine sprocket cover. – Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 301426-11...

  • Page 220: 39/Ignition System

    39/IGNITION SYSTEM Crankshaft position sensor 28.1 Installation location – The crankshaft position sensor is located below the generator cover on the left-hand side of the engine. Component description – The crankshaft position sensor consists of a permanent magnet and an induction coil with a soft iron core.

  • Page 221: 41/Throttle Valve Body

    400687-60 – Press "Continue". – Read the information page on the KTM diagnostics tool and using "Continue" start the calibration process. Info The motor drive moves the throttle valve in circuit A to the "zero" position (throttle valve fully closed position).

  • Page 222: Adjusting The Position Of The Throttle Position Sensor In Circuit A

    – Press "Continue". – Read the information page on the KTM diagnostics tool and using "Continue" start the calibration process. Info The motor drive moves the throttle valve in circuit A to the "zero" position (throttle valve fully closed position).

  • Page 223: Removing The Throttle Valve Body To Adjust

    41/THROTTLE VALVE BODY Removing the throttle valve body to adjust 29.4 – Remove the air filter. ( p. 67) – Unplug the connector of the manifold absolute pressure sensor  – Take the manifold absolute pressure sensor out of the holder but do not detach the vacuum hoses.

  • Page 224: Reinstalling The Throttle Valve Body When The Adjustments Have Been Made

    41/THROTTLE VALVE BODY Reinstalling the throttle valve body when the adjustments have been made 29.5 – Mount connector with the seal.  – Connect the fuel hose. Mount the spring-loaded band-type clamp using the spe-  cial tool. Pliers for spring-loaded band-type clamp (60029057100) ( p.

  • Page 225: Throttle Position Sensor Circuit B

    41/THROTTLE VALVE BODY Throttle position sensor circuit B 29.6 Installation location – Throttle position sensor circuit B is located on the throttle valve body for cylinder 1 on the right-hand side of the engine. 900025-60 Component description – The throttle position sensor has a linear characteristic line and works like a variable resistor.

  • Page 226: Connecting The Vacuum Hand Pump To The Manifold Absolute Pressure Sensor

    41/THROTTLE VALVE BODY at: 400 mbar (5.8 psi) 1.77… 1.83 V at: 450 mbar (6.53 psi) 1.92… 1.98 V at: 800 mbar (11.6 psi) 2.97… 3.03 V at: 850 mbar 3.12… 3.18 V (12.33 psi) at: 900 mbar 3.27… 3.33 V (13.05 psi) at: 950 mbar 3.42…...

  • Page 227: Ambient Air Pressure Sensor

    41/THROTTLE VALVE BODY Ambient air pressure sensor 29.9 Installation location – The ambient air pressure sensor is located on the right-hand side of the frame. Component description – The processing electronics and a measuring cell are located in the housing of the ambient air pressure sensor.

  • Page 228: Rollover Sensor

    41/THROTTLE VALVE BODY Function description – The injector is supplied with battery voltage by the power relay. The EFI control unit calculates the amount of fuel required and grounds the injector via the amplifi- cation stage in the EFI control unit. The longer the injector is connected to ground, the greater the amount of fuel injected.

  • Page 229: Efi Control Unit

    Select "Change VIN - New identity". 400687-60 – Press "Continue". – Read the information page on the KTM diagnostics tool and using "Continue" start the coding process. – Overwrite the entry under the "Please enter VIN:" heading. – Press "Continue".

  • Page 230: Flashing The Efi Control Unit

    41/THROTTLE VALVE BODY – Overwrite the entry under the "Please enter VIN:" heading. – Press "Continue". – Select "Code entry". – "Please enter the Code" – Press "Continue". The new VIN is written to the EFI control unit. – Switch to the main menu. –...

  • Page 231: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Possible cause Ignition keys (all) have not been activated ( p. 229) Ignition keys (all) have not been activated –...
  • Page 232 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Possible cause ICU antenna - value not plausible ( p. 230) ICU antenna - coil antenna has an open ( p.
  • Page 233 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 14 Immobilizer indicator lamp flashes 1x short, 1 second pause, 4x short Possible cause Malfunction in transponder of black ignition key ( p. 231) Malfunction in transponder of black ignition key –...
  • Page 234 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 15 Immobilizer indicator lamp flashes 1x short, 1 second pause, 5x short Possible cause Ignition key has not been activated ( p. 232) Ignition key has not been activated – Activate/deactivate the ignition key.
  • Page 235 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 16 Immobilizer indicator lamp flashes 1x short, 1 second pause, 6x short Possible cause Malfunction, encryption, immobilizer control unit to black ignition key ( p. 233) – Last measure if none of the doc- Activate/deactivate the ignition key.
  • Page 236 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Possible cause Immobilizer control unit not activated ( p. 234) Immobilizer control unit not activated – Activate the ICU. ( p.
  • Page 237 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Possible cause Malfunction, encryption query from EFI control unit to immobilizer control unit ( p. 235) Malfunction, encryption query from EFI control unit to immobilizer control unit –...
  • Page 238 32 Immobilizer indicator lamp flashes 3x short, 1 second pause, 2x short Possible cause Malfunction in CAN bus communication ( p. 236) Malfunction in CAN bus communication – Read out the trouble code memory using the KTM diagnostics tool.
  • Page 239 IMMOBILIZER BLINK CODE Blink code of immobilizer indi- cator lamp 60 Immobilizer indicator lamp flashes 6x short Possible cause E²PROM malfunction ( p. 237) E²PROM malfunction – Change the immobilizer control unit.

  • Page 240: Engine Control Trouble Code

    Select "Lambda sensor heater cylinder 1". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Lambda sensor Lambda sensor cylinder 1 voltage "HEGO1AD" at test start Lambda sensor ≤ 0.5 V Lambda sensor cylinder 1 voltage "HEGO1AD"...
  • Page 241 ENGINE CONTROL TROUBLE CODE Lambda sensor heater cylinder 1 - check the resistance – Measure the resistance between the specified points. Lambda sensor cylinder 1, connector CE pin 1 – Lambda sensor cylinder 1, connector CE pin 2 Lambda sensor heater 11.7…...
  • Page 242 ENGINE CONTROL TROUBLE CODE 600850-12 400646-10 Lambda sensor heater cylinder 1 - check the control wire for opens – Measure the resistance between the specified points. Break out box CO pin 33 – Lambda sensor cylinder 1, connector CA pin 2 ≤...
  • Page 243 ENGINE CONTROL TROUBLE CODE 600850-12 400658-10 Lambda sensor heater cylinder 1 - checking the control wire for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Break out box CO pin 33 – Measuring point Ground (−) ∞...
  • Page 244 Select "Lambda sensor heater cylinder 1". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Lambda sensor Lambda sensor cylinder 1 voltage "HEGO1AD" at test start Lambda sensor ≤ 0.5 V Lambda sensor cylinder 1 voltage "HEGO1AD"...
  • Page 245 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Replace the lambda sensor cylinder 1. » If the specifications have been met: – Check the next possible cause: Lambda sensor heater cylinder 1 - the signal wire has a short circuit to plus (terminal 30) ( p.
  • Page 246 ENGINE CONTROL TROUBLE CODE » If the specifications have been met: – Contact customer service.
  • Page 247 Select "Lambda sensor heater cylinder 2". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Lambda sensor Lambda sensor cylinder 2 voltage "HEGO2AD" at the test start Lambda sensor ≤...
  • Page 248 ENGINE CONTROL TROUBLE CODE Lambda sensor heater cylinder 2 - check the resistance. – Measure the resistance between the specified points. Lambda sensor cylinder 2, connector CE pin 1 – Lambda sensor cylinder 2, connector CE pin 2 Lambda sensor heater 11.7…...
  • Page 249 ENGINE CONTROL TROUBLE CODE 600850-12 400646-10 Lambda sensor heater cylinder 2 - checking the control wire for opens – Measure the resistance between the specified points. Break out box CO pin 15 – Lambda sensor cylinder 2, connector CA pin 2 ≤...
  • Page 250 ENGINE CONTROL TROUBLE CODE 600850-12 400658-10 Lambda sensor heater cylinder 2 - checking the control wire for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Break out box CO pin 15 – Measuring point Ground (−) ∞...
  • Page 251 Select "Lambda sensor heater cylinder 2". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Lambda sensor Lambda sensor cylinder 2 voltage "HEGO2AD" at the test start Lambda sensor ≤...
  • Page 252 ENGINE CONTROL TROUBLE CODE Lambda sensor heater cylinder 2 - check the resistance. – Measure the resistance between the specified points. Lambda sensor cylinder 2, connector CE pin 1 – Lambda sensor cylinder 2, connector CE pin 2 Lambda sensor heater 11.7…...
  • Page 253 ENGINE CONTROL TROUBLE CODE ∞ Ω Resistance » If the specifications have not been met: – Check the cable from EFI control unit connector CO ( p. 397) pin 15 to connector CA ( p. 396) pin 2 for a short circuit to ignition plus (terminal 15).
  • Page 254 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground (...
  • Page 255 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to sensor ground Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) Manifold absolute pressure sensor cylinder 1 is disconnected. ( p.
  • Page 256 ENGINE CONTROL TROUBLE CODE 400590-10 400658-10 Manifold absolute pressure sensor cylinder 1 - checking the power supply – Measure the voltage between the specified points. Manifold absolute pressure sensor cylinder 1, connector DP pin 1 – Measuring point Ground (−) Voltage 4.9…...
  • Page 257 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Manifold absolute pressure sensor cylinder 1 - the signal wire has an open (...
  • Page 258 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 1 - the signal wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Manifold absolute pressure sensor cylinder 1 is disconnected.
  • Page 259 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Manifold absolute pressure sensor cylinder 1 is disconnected.
  • Page 260 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 1 - check the signal wire for a short circuit to the sensor power supply – Measure the resistance between the specified points. Break Out Box AO pin 3 – Break Out Box AO pin 1 ∞...
  • Page 261 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Intake air temperature sensor - value not plausible ( p.
  • Page 262 ENGINE CONTROL TROUBLE CODE – Replace the intake air temperature sensor. » If the specifications have been met: – Check the next possible cause: Intake air temperature sensor - the signal wire has a short circuit to ground (ter- minal 31) ( p.
  • Page 263 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Intake air temperature sensor - the signal wire has a short circuit to plus (terminal 30) ( p.
  • Page 264 ENGINE CONTROL TROUBLE CODE 600850-11 400658-10 Intake air temperature sensor - check the signal wire for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box AO pin 22 – Measuring point Ground (−) ≤...
  • Page 265 ENGINE CONTROL TROUBLE CODE Intake air temperature sensor - the signal wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. 600850-11 400650-10 Intake air temperature sensor - check the signal wire for opens –...
  • Page 266 ENGINE CONTROL TROUBLE CODE Intake air temperature sensor - value not plausible Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Intake air temperature sensor - check the resistance –...
  • Page 267 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Cylinder 1 coolant temperature sensor - value not plausible ( p.
  • Page 268 ENGINE CONTROL TROUBLE CODE Resistance at: 40 °C (104 °F) 1.04… 1.27 kΩ 730… 892 Ω Resistance at: 50 °C (122 °F) 526… 642 Ω Resistance at: 60 °C (140 °F) 385… 471 Ω Resistance at: 70 °C (158 °F) 286…...
  • Page 269 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector AO ( p. 392) pin 9 to con- nector AX ( p. 395) pin 2 for a short circuit to sensor ground. » If the specifications have been met: –...
  • Page 270 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Cylinder 1 coolant temperature sensor - value not plausible ( p.
  • Page 271 ENGINE CONTROL TROUBLE CODE Resistance at: 0 °C (32 °F) 5.17… 6.31 kΩ Resistance at: 10 °C (50 °F) 3.33… 4.07 kΩ Resistance at: 20 °C (68 °F) 2.21… 2.70 kΩ Resistance at: 30 °C (86 °F) 1.49… 1.83 kΩ Resistance at: 40 °C (104 °F) 1.04…...
  • Page 272 ENGINE CONTROL TROUBLE CODE Engine coolant temperature sensor cylinder 1 - check the signal wire for a short circuit to ignition plus (terminal 15) – Measure the resistance between the specified points. Break Out Box AO pin 9 – Break Out Box AO pin 20 ∞...
  • Page 273 ENGINE CONTROL TROUBLE CODE – Check the next possible cause: Engine coolant temperature sensor cylinder 1 - the ground wire has an open ( p. 271) Engine coolant temperature sensor cylinder 1 - the ground wire has an open Condition The ignition is off.
  • Page 274 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Throttle position sensor circuit A - the power supply is interrupted ( p.
  • Page 275 ENGINE CONTROL TROUBLE CODE 400584-10 400658-10 Throttle position sensor circuit A - check the power supply – Measure the voltage between the specified points. Throttle position sensor circuit A, connector AR pin 1 – Measuring point Ground (−) Voltage 4.9… 5.1 V »...
  • Page 276 ENGINE CONTROL TROUBLE CODE Throttle position sensor circuit A - the signal wire has a short circuit to sensor ground Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Throttle position sensor circuit A is disconnected.
  • Page 277 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Throttle position sensor circuit A - the signal wire has a short circuit to plus (terminal 30) ( p.
  • Page 278 ENGINE CONTROL TROUBLE CODE 600850-11 400658-10 Throttle position sensor circuit A - check the signal wire for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box AO pin 10 – Measuring point Ground (−) ≤...
  • Page 279 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector AO ( p. 392) pin 10 to con- nector CQ ( p. 398) pin 6 for a short circuit to the sensor power supply. – Check the cable from connector CP ( p.
  • Page 280 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value does not correspond to the nominal value: – Check the next possible cause: Lambda sensor cylinder 1 - value not plausible ( p.
  • Page 281 ENGINE CONTROL TROUBLE CODE Lambda sensor cylinder 1 - check the voltage – Measure the voltage between the specified points. Lambda sensor connector CE‑CA pin 3 – Lambda sensor connector CE‑CA pin 4 Lambda sensor Lambda sensor cylinder 1 voltage 0.2…...
  • Page 282 ENGINE CONTROL TROUBLE CODE Lambda sensor cylinder 1 - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Lambda sensor for cylinder 1 is disconnected.
  • Page 283 ENGINE CONTROL TROUBLE CODE Lambda sensor cylinder 1 - check the signal wire for a short circuit to the sensor power supply. – Measure the resistance between the specified points. Break Out Box AO pin 11 – Break Out Box AO pin 1 ∞...
  • Page 284 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check EFI control unit connector AO ( p. 392) pin 7 and connector CA pin 3. – Check the cable from EFI control unit connector AO ( p.
  • Page 285 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value does not correspond to the nominal value: – Check the next possible cause: Lambda sensor cylinder 2 - value not plausible ( p.
  • Page 286 ENGINE CONTROL TROUBLE CODE Lambda sensor cylinder 2 - check the voltage – Measure the voltage between the specified points. Lambda sensor connector CE‑CA pin 3 – Lambda sensor connector CE‑CA pin 4 Lambda sensor Lambda sensor cylinder 2 voltage 0.2…...
  • Page 287 ENGINE CONTROL TROUBLE CODE Lambda sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Lambda sensor for cylinder 2 is disconnected.
  • Page 288 ENGINE CONTROL TROUBLE CODE Lambda sensor cylinder 2 - check the signal wire for a short circuit to the sensor power supply. – Measure the resistance between the specified points. Break Out Box AO pin 12 – Break Out Box AO pin 1 ∞...
  • Page 289 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check EFI control unit connector AO ( p. 392) pin 7 and connector CA pin 3. – Check the cable from EFI control unit connector AO ( p.
  • Page 290 Press "Continue". – Select "Injector cylinder 1". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Injector Operating noise » If the specifications have been met: – Delete trouble code.
  • Page 291 ENGINE CONTROL TROUBLE CODE – Replace the injector cylinder 1. » If the specifications have been met: – Check the next possible cause: Injector cylinder 1 - there is a power supply fault ( p. 289) Injector cylinder 1 - there is a power supply fault Condition The ignition is on.
  • Page 292 ENGINE CONTROL TROUBLE CODE – Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to plus (termi- nal 30). » If the specifications have been met: –...
  • Page 293 ENGINE CONTROL TROUBLE CODE – Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to the sensor power supply. » If the specifications have been met: –...
  • Page 294 ENGINE CONTROL TROUBLE CODE – Check the cable from connector CP ( p. 398) pin 2.5 to connector DQ ( p. 400) pin 2 for a short circuit to ground (termi- nal 31). » If the specifications have been met: –...
  • Page 295 Press "Continue". – Select "Injector cylinder 2". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Injector Operating noise » If the specifications have been met: – Delete trouble code.
  • Page 296 ENGINE CONTROL TROUBLE CODE – Change the injector cylinder 2. » If the specifications have been met: – Check the next possible cause: Injector cylinder 2 - the power supply is faulty ( p. 294) Injector cylinder 2 - the power supply is faulty Condition The ignition is on.
  • Page 297 ENGINE CONTROL TROUBLE CODE – Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to plus (termi- nal 30). » If the specifications have been met: –...
  • Page 298 ENGINE CONTROL TROUBLE CODE – Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to the sensor power supply. » If the specifications have been met: –...
  • Page 299 ENGINE CONTROL TROUBLE CODE – Check the cable from connector CP ( p. 398) pin 2.9 to connector DQ ( p. 401) pin 2 for a short circuit to ground (termi- nal 31). » If the specifications have been met: –...
  • Page 300 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Throttle position sensor circuit B - the power supply is interrupted ( p.
  • Page 301 ENGINE CONTROL TROUBLE CODE 400582-10 400658-10 Throttle position sensor circuit B - check the power supply – Measure the voltage between the specified points. Throttle position sensor circuit B, connector AM pin 2 – Measuring point Ground (−) Voltage 4.9… 5.1 V »...
  • Page 302 ENGINE CONTROL TROUBLE CODE Throttle position sensor circuit B - the signal wire has a short circuit to sensor ground Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Throttle position sensor circuit B is disconnected.
  • Page 303 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Throttle position sensor circuit B - the signal wire has a short circuit to plus (terminal 30) ( p.
  • Page 304 ENGINE CONTROL TROUBLE CODE 600850-11 400658-10 Throttle position sensor circuit B - check the signal wire for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box AO pin 2 – Measuring point Ground (−) ≤...
  • Page 305 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector AO ( p. 392) pin 2 to con- nector CQ ( p. 398) pin 10 for a short circuit to the sensor power supply. – Check the cable from connector CP ( p.
  • Page 306 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » The specifications have not been met: – Check the next possible cause: Crankshaft position sensor - value not plausible ( p.
  • Page 307 ENGINE CONTROL TROUBLE CODE Crankshaft position sensor - check the resistance – Measure the resistance between the specified points. Crankshaft position sensor, connector AT pin 1 – Crankshaft position sensor, connector AT pin 2 Crankshaft position sensor 80… 120 Ω Resistance at: 20 °C (68 °F) »...
  • Page 308 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector AO ( p. 392) pin 14 to connector AL ( p. 391) pin 2 for a short circuit to ground (terminal 31). – Check the cable from EFI control unit connector AO ( p.
  • Page 309 ENGINE CONTROL TROUBLE CODE Crankshaft position sensor - the signal wires have a short circuit to ignition plus (terminal 15) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The crankshaft position sensor is connected.
  • Page 310 Press "Continue". – Select "Ignition cylinder 1". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Spark plug Operating noise » If the specifications have been met: – Delete trouble code.
  • Page 311 ENGINE CONTROL TROUBLE CODE Ignition coil cylinder 1 - check the resistance – Measure the resistance between the specified points. Ignition coil pin 1 – Ignition coil pin 2 Ignition coil 1.105… 1.495 Ω Primary winding resistance at: 20 °C (68 °F) »...
  • Page 312 ENGINE CONTROL TROUBLE CODE 600850-12 600850-11 Ignition coil cylinder 1 - check the control wire for a short circuit to sensor ground. – Measure the resistance between the specified points. Break out box CO pin 29 – Break Out Box AO pin 7 ∞...
  • Page 313 ENGINE CONTROL TROUBLE CODE 600850-12 600850-11 Ignition coil cylinder 1 - check the control wire for a short circuit to ignition plus (terminal 15). – Measure the resistance between the specified points. Break out box CO pin 29 – Break Out Box AO pin 20 ∞...
  • Page 314 ENGINE CONTROL TROUBLE CODE Ignition coil cylinder 1 - the power supply is interrupted Condition The ignition is on. The diagnostics tool is connected and active. EFI control unit is connected. ( p. 227) Ignition coil cylinder 1 is disconnected. ( p.
  • Page 315 Press "Continue". – Select "Ignition cylinder 2". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Spark plug Operating noise » If the specifications have been met: – Delete trouble code.
  • Page 316 ENGINE CONTROL TROUBLE CODE Ignition coil cylinder 2 - check the resistance – Measure the resistance between the specified points. Ignition coil pin 1 – Ignition coil pin 2 Ignition coil 1.105… 1.495 Ω Primary winding resistance at: 20 °C (68 °F) »...
  • Page 317 ENGINE CONTROL TROUBLE CODE 600850-12 600850-11 Ignition coil cylinder 2 - check the control wire for a short circuit to sensor ground. – Measure the resistance between the specified points. Break out box CO pin 26 – Break Out Box AO pin 7 ∞...
  • Page 318 ENGINE CONTROL TROUBLE CODE 600850-12 600850-11 Ignition coil cylinder 2 - check the control wire for a short circuit to ignition plus (terminal 15). – Measure the resistance between the specified points. Break out box CO pin 26 – Break Out Box AO pin 20 ∞...
  • Page 319 ENGINE CONTROL TROUBLE CODE Ignition coil cylinder 2 - the power supply is interrupted Condition The ignition is on. The diagnostics tool is connected and active. EFI control unit is connected. ( p. 227) Ignition coil cylinder 2 is disconnected. ( p.
  • Page 320 – Select "Exhaust air injection valve SLS on/off". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Secondary air valve Operating noise » If the specifications have been met: –...
  • Page 321 ENGINE CONTROL TROUBLE CODE – Change the secondary air valve. » If the specifications have been met: – Check the next possible cause: Secondary air valve - the control wire has a short circuit to ground (terminal 31) p. 319) Secondary air valve - the control wire has a short circuit to ground (terminal 31) Condition The ignition is off.
  • Page 322 ENGINE CONTROL TROUBLE CODE Secondary air valve - the power supply is faulty Condition The ignition is on. EFI control unit is connected. ( p. 227) The exhaust air injection valve is disconnected. ( p. 190) 400648-10 400658-10 Secondary air valve - check the power supply –...
  • Page 323 ENGINE CONTROL TROUBLE CODE Secondary air valve - the control wire has a short circuit to sensor ground Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The exhaust air injection valve is disconnected.
  • Page 324 – Select "Exhaust air injection valve SLS on/off". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Secondary air valve Operating noise » If the specifications have been met: –...
  • Page 325 ENGINE CONTROL TROUBLE CODE Secondary air valve - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The exhaust air injection valve is disconnected.
  • Page 326 Press "Continue". – Select "motor drive circuit A". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Idle speed control Operating noise » If the specifications have been met: –...
  • Page 327 ENGINE CONTROL TROUBLE CODE Motor drive circuit A phase A - value not plausible Condition The ignition is off. Connector CP is disconnected. ( p. 398) Motor drive circuit A phase A - check the resistance – Measure the resistance between the specified points. Connector CP pin 2.12 –...
  • Page 328 ENGINE CONTROL TROUBLE CODE Motor drive circuit A phase A - check the signal wire for opens – Measure the resistance between the specified points. Break out box CO pin 7 – Break out box CO pin 23 Motor drive circuit A 7.11…...
  • Page 329 ENGINE CONTROL TROUBLE CODE 600850-12 400658-10 Motor drive circuit A phase A - check the signal wire for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Break out box CO pin 23 – Measuring point Ground (−) ∞...
  • Page 330 ENGINE CONTROL TROUBLE CODE Motor drive circuit A phase A - the signal wire has a short circuit to sensor ground Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. 600850-12 600850-11 Motor drive circuit A phase A - check the signal wire for a short circuit to sensor ground...
  • Page 331 ENGINE CONTROL TROUBLE CODE » If the specifications have been met: – Check the next possible cause: Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30) ( p. 329) Motor drive circuit A phase A - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off.
  • Page 332 ENGINE CONTROL TROUBLE CODE – Check connector CP ( p. 398) pin 2.8 to connector AE ( p. 391) pin 1 for a short circuit to plus (terminal 30). – Check the cable from EFI control unit connector CO ( p.
  • Page 333 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check the cable from EFI control unit connector CO ( p. 397) pin 11 to connector CQ ( p. 398) pin 8 for a short circuit to ignition plus (terminal 15).
  • Page 334 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: EFI control unit - the power supply is faulty ( p.
  • Page 335 ENGINE CONTROL TROUBLE CODE Info For measurement the measuring points must be subjected to a 12V/21W bulb load. The value may not differ from the battery voltage "VBAT" by more than 1 V. » If the specifications have not been met: –...
  • Page 336 ENGINE CONTROL TROUBLE CODE Info For measurement the measuring points must be subjected to a 12V/21W bulb load. The value may not differ from the battery voltage "VBAT" by more than 1 V. » If the specifications have not been met: –...
  • Page 337 ENGINE CONTROL TROUBLE CODE Blink code EFI warning lamp (MIL) 62 EFI warning lamp (MIL) flashes 6x long, 5x short Display on diagnostic tool P0603 "E²PROM" "Fault" Error level condition Read data and write data differ. Function check Flashing the EFI control unit ( p.
  • Page 338 – Select "Motor drive circuit B". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Throttle position sensor circuit B Voltage "TAPAD" 0.156… 4.824 V » If the specifications have been met: –...
  • Page 339 ENGINE CONTROL TROUBLE CODE – Read out the trouble code memory using the KTM diagnostics tool. » The specifications have not been met: – Check the next possible cause: Motor drive circuit B phase A - value not plausible ( p.
  • Page 340 ENGINE CONTROL TROUBLE CODE Motor drive circuit B phase A - the signal wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Connector CP is connected.
  • Page 341 ENGINE CONTROL TROUBLE CODE Motor drive circuit B phase A - the signal wire has a short circuit to ground (terminal 31) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. 600850-12 400658-10 Motor drive circuit B phase A - check the signal wire for a short circuit to ground (terminal 31)
  • Page 342 ENGINE CONTROL TROUBLE CODE » If the specifications have been met: – Check the next possible cause: Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground ( p. 340) Motor drive circuit B phase A - the signal wire has a short circuit to sensor ground Condition The ignition is off.
  • Page 343 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector CO ( p. 397) pin 4 to connector CQ ( p. 398) pin 3 for a short circuit to sensor ground. – Check connector CP ( p. 398) pin 2.3 to connector CA ( p.
  • Page 344 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector CO ( p. 397) pin 12 to connector CQ ( p. 398) pin 7 for a short circuit to plus (terminal 30). – Check connector CP ( p.
  • Page 345 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check the cable from EFI control unit connector CO ( p. 397) pin 12 to connector CQ ( p. 398) pin 7 for a short circuit to ignition plus (terminal 15).
  • Page 346 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty (...
  • Page 347 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 1 - the vacuum hose to the cylinder head is faulty – Manifold absolute pressure sensor cylinder 1 - check the vacuum hose to the cylinder head for leaks. Vacuum hose Is OK.
  • Page 348 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty (...
  • Page 349 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 2 - the vacuum hose to the cylinder head is faulty – Manifold absolute pressure sensor cylinder 2 - check the vacuum hose to the cylinder head for leaks. Vacuum hose Is OK.
  • Page 350 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Ambient air pressure sensor - the signal wire has a short circuit to sensor ground ( p.
  • Page 351 ENGINE CONTROL TROUBLE CODE Ambient air pressure sensor - check the signal wire for a short circuit to sensor ground – Measure the resistance between the specified points. Ambient air pressure sensor connector DP pin 2 – Ambient air pressure sen- sor connector DP pin 3 ∞...
  • Page 352 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check connector DP pin 1. – Check the cable from connector DP pin 1 to the next node in the wiring harness for opens. » If the specifications have been met: –...
  • Page 353 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Ambient air pressure sensor - the signal wire has an open (...
  • Page 354 ENGINE CONTROL TROUBLE CODE Ambient air pressure sensor - the signal wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The ambient air pressure sensor is disconnected. ( p.
  • Page 355 ENGINE CONTROL TROUBLE CODE Ambient air pressure sensor - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The ambient air pressure sensor is disconnected.
  • Page 356 ENGINE CONTROL TROUBLE CODE Ambient air pressure sensor - check the signal wire for a short circuit to the sensor power supply – Measure the resistance between the specified points. Break Out Box AO pin 23 – Break Out Box AO pin 1 ∞...
  • Page 357 Press "Continue". – Select "Fuel pump relay function test". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Fuel pump Operating noise » If the specifications have been met: –...
  • Page 358 ENGINE CONTROL TROUBLE CODE – Check the next possible cause: Fuel pump relay - the control wire has an open ( p. 356) Fuel pump relay - the control wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p.
  • Page 359 ENGINE CONTROL TROUBLE CODE – Check the cable from connector EB pin 1 to the next node in the wiring harness for opens. » If the specifications have been met: – Check the next possible cause: Fuel pump relay - the control wire has a short circuit to ground (terminal 31) ( p.
  • Page 360 ENGINE CONTROL TROUBLE CODE – Check the cable from connector ET ( p. 402) pin 15 to connector EB ( p. 401) pin 2 for a short circuit to sensor ground. » If the specifications have been met: – Contact customer service.
  • Page 361 Press "Continue". – Select "Fuel pump relay function test". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Fuel pump Operating noise » If the specifications have been met: –...
  • Page 362 ENGINE CONTROL TROUBLE CODE Fuel pump relay - the control wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The fuel pump relay is disconnected.
  • Page 363 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Side stand switch - the signal wire has a short circuit to sensor ground ( p.
  • Page 364 ENGINE CONTROL TROUBLE CODE – Check the next possible cause: Side stand switch - the signal wire has a short circuit to ground (terminal 31) p. 362) Side stand switch - the signal wire has a short circuit to ground (terminal 31) Condition The ignition is off.
  • Page 365 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Rollover sensor - there is an open in the power supply ( p.
  • Page 366 ENGINE CONTROL TROUBLE CODE 400583-10 400658-10 Rollover sensor - check if there is an open in the power supply – Measure the voltage between the specified points. Rollover sensor connector AP pin 6 – Measuring point Ground (−) Voltage 4.9… 5.1 V »...
  • Page 367 ENGINE CONTROL TROUBLE CODE Rollover sensor - check the signal wire for a short circuit to sensor ground – Measure the resistance between the specified points. Break Out Box AO pin 4 – Break Out Box AO pin 7 ∞ Ω Resistance »...
  • Page 368 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Rollover sensor - the signal wire has a short circuit to plus (terminal 30) ( p.
  • Page 369 ENGINE CONTROL TROUBLE CODE 600850-11 400658-10 Rollover sensor - check the signal wire for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box AO pin 4 – Measuring point Ground (−) Voltage <...
  • Page 370 ENGINE CONTROL TROUBLE CODE Rollover sensor - the signal wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The rollover sensor is disconnected. ( p.
  • Page 371 ENGINE CONTROL TROUBLE CODE Blink code EFI warning lamp (MIL) 81 EFI warning lamp (MIL) flashes 8x long, 1x short Display on diagnostic tool P1650 "Immobilizer control unit" "Circuit fault" Possible cause The ICU is faulty ( p. 369) – Last measure if none of the doc- Correct the immobilizer fault.
  • Page 372 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is below the nominal value: – Check the next possible cause: Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground (...
  • Page 373 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to sensor ground Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) Manifold absolute pressure sensor cylinder 2 is disconnected. ( p.
  • Page 374 ENGINE CONTROL TROUBLE CODE 400590-10 400658-10 Manifold absolute pressure sensor cylinder 2 - checking the power supply – Measure the voltage between the specified points. Manifold absolute pressure sensor cylinder 2 connector DP pin 1 – Measuring point Ground (−) Voltage 4.9…...
  • Page 375 – Delete trouble code. – Take a test ride. – Read out the trouble code memory using the KTM diagnostics tool. » If the displayed value is above the nominal value: – Check the next possible cause: Manifold absolute pressure sensor cylinder 2 - the signal wire has an open (...
  • Page 376 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 2 - the signal wire has an open Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Manifold absolute pressure sensor cylinder 2 is disconnected.
  • Page 377 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 2 - the signal wire has a short circuit to plus (terminal 30) Condition The ignition is off. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. Manifold absolute pressure sensor cylinder 2 is disconnected.
  • Page 378 ENGINE CONTROL TROUBLE CODE Manifold absolute pressure sensor cylinder 2 - check the signal wire for a short circuit to the sensor power supply – Measure the resistance between the specified points. Break Out Box AO pin 24 – Break Out Box AO pin 1 ∞...
  • Page 379 ENGINE CONTROL TROUBLE CODE Blink code EFI warning lamp (MIL) 91 EFI warning lamp (MIL) flashes 9x long, 1x short Display on diagnostic tool 1690 "CAN bus communication error" Circuit fault: ≥ 3 s Error level condition CAN communication: data format and CAN reply - incorrect data format: ≥ 10 s Possible cause Combination instrument - the CAN-high wire has an open ( p.
  • Page 380 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check EFI control unit connector CO ( p. 397) pin 19 and connector EV pin 4. – Check the cable from EFI control unit connector CO ( p.
  • Page 381 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check EFI control unit connector CO ( p. 397) pin 19 and connector DO pin 6. – Check the cable from EFI control unit connector CO ( p.
  • Page 382 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check the cable from connector EV ( p. 403) pin 4 to EFI control unit connector CO ( p. 397) pin 19 for a short circuit to ground (terminal 31).
  • Page 383 ENGINE CONTROL TROUBLE CODE CAN-high - the signal wire has a short circuit to sensor ground Condition The ignition is off. The diagnostics tool is disconnected. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The CAN bus terminating resistor is disconnected.
  • Page 384 ENGINE CONTROL TROUBLE CODE 600850-12 600850-11 CAN-low - check the signal wire for a short circuit to sensor ground – Measure the resistance between the specified points. Break out box CO pin 20 – Break Out Box AO pin 7 ∞...
  • Page 385 ENGINE CONTROL TROUBLE CODE CAN bus terminating resistor - the CAN-low wire has an open Condition The ignition is off. The diagnostics tool is disconnected. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The CAN bus terminating resistor is disconnected.
  • Page 386 ENGINE CONTROL TROUBLE CODE – Check the next possible cause: Connector CU - the CAN-low wire has an open ( p. 384) Connector CU - the CAN-low wire has an open Condition The ignition is off. The diagnostics tool is disconnected. The EFI control unit is disconnected.
  • Page 387 ENGINE CONTROL TROUBLE CODE – Check the cable from EFI control unit connector CO ( p. 397) pin 19 to connector AP pin 2 for opens. » If the specifications have been met: – Check the next possible cause: Diagnostics connector - the CAN-low wire has an open ( p.
  • Page 388 ENGINE CONTROL TROUBLE CODE » If the specifications have not been met: – Check the cable from connector EV ( p. 403) pin 4 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuit to plus (terminal 30).
  • Page 389 ENGINE CONTROL TROUBLE CODE CAN-high - the signal wire has a short circuit to ignition plus (terminal 15) Condition The ignition is off. The diagnostics tool is disconnected. The EFI control unit is disconnected. ( p. 227) The break out box is connected to the wiring harness. The CAN bus terminating resistor is disconnected.
  • Page 390 ENGINE CONTROL TROUBLE CODE 600850-12 600850-11 CAN-low - check the signal wire for a short circuit to ignition plus (terminal 15) – Measure the resistance between the specified points. Break out box CO pin 20 – Break Out Box AO pin 20 ∞...
  • Page 391 ENGINE CONTROL TROUBLE CODE – Check the cable from connector AT ( p. 395) pin 2 to the EFI control unit connector CO ( p. 397) pin 19 for a short circuit to plus (terminal 30). – Check the cable from connector AP ( p.
  • Page 392 ENGINE CONTROL TROUBLE CODE CAN bus terminating resistor - check the resistor. – Measure the resistance between the specified points. CAN bus terminating resistor pin 1 – CAN bus terminating resistor pin 2 CAN bus terminating resistor 108… 132 Ω Resistance at: 20 °C (68 °F) »...

  • Page 393: Connector Overview

    CONNECTOR OVERVIEW Motor drive circuit A connector AE 32.1 Pin overview Motor drive circuit A phase BP, control wire Motor drive circuit A phase AN, control wire Motor drive circuit A phase AP, control wire Motor drive circuit A phase BN, control wire 400682-10 Connector AI 32.2...

  • Page 394: Throttle Position Sensor Circuit B, Connector Am

    CONNECTOR OVERVIEW Throttle position sensor circuit B, connector AM 32.6 Pin overview Signal wire Power supply Sensor ground 400582-10 Gear position sensor, connector AM 32.7 Pin overview Signal wire 3rd gear Signal wire 2nd gear Signal wire, idle 400582-10 Fuel pump connector AM 32.8 Pin overview Power supply...

  • Page 395: Diagnostic Connection Plug Ap

    Clutch switch, signal wire Side stand switch, signal wire Diagnostic connection plug AP 32.11 Pin overview System voltage CAN high CAN low K bus signal wire to KTM diagnostics tool Not assigned Ground 400583-10 Rollover sensor connector AP 32.12 Pin overview Not assigned...

  • Page 396: Throttle Position Sensor Circuit B, Connector Ar

    CONNECTOR OVERVIEW Throttle position sensor circuit B, connector AR 32.14 Pin overview Signal wire System voltage Sensor ground 400584-10 Fuel pump connector AR 32.15 Pin overview Power supply Not assigned Ground 400584-10 Side stand switch, connector AR 32.16 Pin overview System voltage Sensor ground Signal wire...

  • Page 397: Can Bus Terminating Resistor Connector At

    CONNECTOR OVERVIEW CAN bus terminating resistor connector AT 32.19 Pin overview CAN low CAN high 400585-10 Crankshaft position sensor, connector AT 32.20 Pin overview Signal wire Signal wire 400585-10 Clutch switch connector AT 32.21 Pin overview Signal wire Ground 400585-10 Engine coolant temperature sensor cylinder 1 connector AX 32.22 Pin overview...

  • Page 398: Lambda Sensor Cylinder 1, Connector Ca

    CONNECTOR OVERVIEW Lambda sensor cylinder 1, connector CA 32.24 Pin overview Power supply, lambda sensor heater Lambda sensor heater, control wire Sensor ground Signal wire 400646-10 Lambda sensor cylinder 2, connector CA 32.25 Pin overview Power supply, lambda sensor heater Lambda sensor heater, control wire Sensor ground Signal wire...

  • Page 399: Connector Cm

    CONNECTOR OVERVIEW Connector CM 32.29 Pin overview Sensor ground Signal wire 400650-10 Connector CO 32.30 Pin overview Not assigned Fuel pump relay, control wire Motor drive circuit A phase BN, control wire Motor drive circuit B phase BN, control wire Injector cylinder 1, control wire Injector cylinder 2, control wire Motor drive circuit A phase AN, control wire...

  • Page 400: Connector Cp

    CONNECTOR OVERVIEW Connector CP 32.31 Pin overview Not assigned Sensor ground Motor drive circuit B phase BN, control wire Motor drive circuit A phase BN, control wire Injector cylinder 1, control wire Throttle position sensor circuit A, signal wire Motor drive circuit B phase BP, control wire 400651-10 Motor drive circuit A phase BP, control wire Injector cylinder 2, control wire...

  • Page 401: Fuel Evaporation Valve Connector Df

    CONNECTOR OVERVIEW Fuel evaporation valve connector DF 32.34 Pin overview Power supply Control wire 400589-10 Secondary air valve connector DF 32.35 Pin overview Power supply Control wire 400589-10 Electric starter lock control unit, connector DN 32.36 Pin overview Power supply Side stand switch, signal wire Starter auxiliary relay Clutch switch, signal wire...

  • Page 402: Immobilizer Control Unit, Connector Do

    CONNECTOR OVERVIEW Immobilizer control unit, connector DO 32.39 Pin overview Coil antenna Coil antenna Power supply Power supply CAN high Ground 400657-10 CAN low Ambient air pressure sensor connector DP 32.40 Pin overview System voltage Sensor ground Signal wire 400590-10 Manifold absolute pressure sensor cylinder 1, connector DP 32.41 Pin overview...

  • Page 403: Injector Cylinder 2 Connector Dq

    Coil antenna 400685-10 Connector EQ 32.48 Pin overview Not assigned LED alarm system (optional), signal wire K bus wire to KTM diagnostics tool Power supply (terminal 15) CAN high Not assigned Fuel evaporation valve, control wire 400683-10 Power supply (terminal 30)

  • Page 404: Connector Er

    CAN low Connector ER 32.49 Pin overview Not assigned LED alarm system (optional), signal wire K bus wire to KTM diagnostics tool Power supply (terminal 15) CAN high Not assigned Fuel evaporation valve, control wire 400684-10 Power supply (terminal 30)

  • Page 405: Combination Instrument Connector Ev

    CONNECTOR OVERVIEW Fuel pump relay, control wire Power supply, main relay, fuel pump Power supply (terminal 30) Power supply, start auxiliary relay, working circuit Combination instrument connector EV 32.52 Pin overview Power supply Power supply Ground CAN high CAN low Engine coolant temperature sensor cylinder 2, signal wire Engine coolant temperature sensor cylinder 1, signal wire 400645-10...

  • Page 406: Fuel Pump Relay

    CONNECTOR OVERVIEW Fuel pump relay 32.54 Pin overview Control circuit power supply Control wire Fuel pump power supply Working circuit power supply 600852-10 CAN bus terminating resistor 32.55 Pin overview CAN low CAN high 600857-10...

  • Page 407: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 1,195 cm³ (72.92 cu in) Stroke 69 mm (2.72 in) Bore 105 mm (4.13 in) Compression ratio 13.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - valve stem diameter Intake 42 mm (1.65 in) Exhaust...

  • Page 408: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 33.2 Coolant 2.60 l (2.75 qt.) Coolant ( p. 436) Coolant (mixed ready to use) ( p. 436)

  • Page 409: Engine

    TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Camshaft - cam height Intake 39.34… 39.44 mm (1.5488… 1.5528 in) Exhaust 38.59… 38.69 mm (1.5193… 1.5232 in) Camshaft - bearing pin 23.960… 23.980 mm (0.94331… 0.94409 in) Camshaft bearing - radial clearance New condition 0.020…...
  • Page 410 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE New condition 0.030… 0.060 mm (0.00118… 0.00236 in) Wear limit 0.080 mm (0.00315 in) Connecting rod - large end width 20.950… 21.000 mm (0.8248… 0.82677 in) Crankshaft - axial clearance New condition 0.15…...

  • Page 411: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, gear sensor 3 Nm (2.2 lbf ft) Loctite 243™...
  • Page 412 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) Cylinder head screw M11x1.5 Tightening sequence:...

  • Page 413: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chromium molybdenum steel tubing, powder-coated WP Suspension Up Side Down 4354 Fork Shock absorber WP Suspension 4014 VP Suspension travel Front 120 mm (4.72 in) Rear 120 mm (4.72 in) Brake system Front Twin floating disc with radial mount, 4-piston calipers Rear...

  • Page 414: Capacity - Fuel

    120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 36.2 Total fuel tank capacity, 16.5 l (4.36 US gal) Super unleaded (ROZ 98 / RON 98 / PON 94) ( p.

  • Page 415: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 05.18.7E.10 Fork WP Suspension Up Side Down 4354 Compression damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring preload - Preload Adjuster...

  • Page 416: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 17.18.7E.10 Shock absorber WP Suspension 4014 VP Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload...

  • Page 417: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™ – Remaining frame bolts 5 Nm (3.7 lbf ft) ® Screw, brake fluid reservoir of rear 5 Nm (3.7 lbf ft) Loctite 243™...
  • Page 418 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, engine bearer 45 Nm (33.2 lbf ft) ® Screw, shock absorber 45 Nm (33.2 lbf ft) Loctite 243™ ® Screw, side stand 35 Nm (25.8 lbf ft) Loctite 243™ ® Rear sprocket bolt M10x1.25 50 Nm (36.9 lbf ft) Loctite...

  • Page 419: Cleaning/Conservation

    CLEANING/CONSERVATION Cleaning motorcycle 40.1 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 electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 420 CLEANING/CONSERVATION – Clean the chain. ( p. 84)

  • Page 421: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle at the rear. ( p. 13) –...

  • Page 422: Service Schedule

    SERVICE SCHEDULE Important service tasks to be carried out by an authorized KTM-RC8 workshop. 42.1 K10N K75A K150A Engine Change the engine oil and filter, clean the oil screens. ( p. 209) • • • • • Check the valve clearance. ( p.

  • Page 423: Important Service Tasks To Be Carried Out By An Authorized Ktm-Rc8 Workshop. (As Additional Job)

    K75A: every 7,500 km (4,660 mi) K150A: every 15,000 km (9,320 mi) / after every sporting use J1A: annually J2A: every 2 years Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) 42.2 K150N K150A K300A Perform a fork service.

  • Page 424: Wiring Diagram

    WIRING DIAGRAM 1 of 3 43.1 82,177 175,176,144,153,169,182 98,152,147 54,55 24,25 7,8,9,10,14 AU/2 36,37 BI/2 600859-01...
  • Page 425 WIRING DIAGRAM Components Plug-in connector for alarm system (optional) F1‑2 Battery A7 Generator B‑C8 Starter relay with main fuse A6 Fuel pump relay F4 Light relay F5‑6 Power relay F6 Start auxiliary relay F7 Starter motor A‑B6 Fuel pump F5 Voltage regulator/rectifier B8 Ignition/steering lock, ICU antenna A1‑2 Emergency OFF switch, electric starter button A2‑3...
  • Page 426 WIRING DIAGRAM Red-violet Blue-red Brown Brown Brown Brown Black Violet White-black Red-violet Brown White-red Blue-red Yellow-orange Brown White-red White-red Brown Yellow Yellow-red Green-orange Blue-gray Yellow-orange White-red Red-violet Blue-red Yellow-orange White-red Yellow-orange Green Black-green White-red White-red Yellow-orange Yellow-orange Yellow-orange Yellow-orange White-red Yellow-orange...
  • Page 427 WIRING DIAGRAM...

  • Page 428: Of 3

    WIRING DIAGRAM 2 of 3 43.2 100,148,224 99,151 -X13 156,179,218 STR-A3 /1.B4 fuel-A4 /1.B4 CQ/16 -X300 CP/16 238,239 600860-01...
  • Page 429 WIRING DIAGRAM Components Immobilizer control unit A3 Control unit of electric starter lock A5 EFI control unit F4‑7 Side stand switch A4 Intake air temperature sensor F1 Roll angle sensor F1 Lambda sensor (cylinder 2) F1‑2 Lambda sensor (cylinder 1) F2 Ambient air pressure sensor F2‑3 Pressure sensor, induction manifold (cylinder 2) F3 Pressure sensor, induction manifold (cylinder 1) F3...
  • Page 430 WIRING DIAGRAM Black Blue Green-gray Yellow-blue White-yellow Orange White-pink Brown Yellow-brown Gray Black-green Black Red-violet Brown Orange White-violet Pink Blue Black Orange White-orange Black Brown-red Brown Green Black-green White-red Orange Black-blue Brown White-blue Brown-violet Black-blue White-blue Black-brown Black-green White Brown Yellow Brown White-blue...
  • Page 431 WIRING DIAGRAM White-brown Orange White-black Black Green-red Brown Brown-violet Blue Red-violet Black Blue-red Black Black-green Orange Yellow Pink Blue-orange Blue-pink Black-gray Yellow-orange White-red Brown Brown Green White-green Black-blue White-blue Brown-gray Yellow-green Green-orange Blue-brown Black Orange Blue Blue Pink Yellow Brown Black-green Orange Orange...
  • Page 432 WIRING DIAGRAM Violet Blue Yellow Gray Black-blue Green-red White Blue-orange...
  • Page 433 WIRING DIAGRAM...

  • Page 434: Of 3

    WIRING DIAGRAM 3 of 3 43.3 pos. high -B10 -B14 t° AR/3 CW/2 CW/2 AM/3 CX/2 CX/2 EW/4 CX/2 AT/2 AK/2 CW/2 AL/2 AH/2 EV/26 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 170,171 139,160 79,134...
  • Page 435 WIRING DIAGRAM Components Wheel speed sensor D1 Fuel level indicator A4 Ambient air temperature sensor B1 Engine coolant temperature sensor (2nd cylinder) F3 Low beam, high beam, parking light D‑E1 Front right flasher B1 Front left flasher E1 Horn F5‑6 Rear right flasher C8 Brake/tail light C‑D8 License plate lamp D8...
  • Page 436 WIRING DIAGRAM Yellow-blue Yellow-green Black-green Blue-red Black Brown Gray Yellow-blue Green-gray Brown Brown-red Brown Brown Brown Brown Brown Black Violet Yellow Yellow Brown Blue Gray Yellow-green Yellow-green Black-orange Yellow-orange Brown White-red Yellow-orange Brown-violet Black-blue White-blue Black-brown Yellow-green Brown Blue Black-green Brown White Green...
  • Page 437 WIRING DIAGRAM Black-blue Brown Yellow-orange Brown Brown Brown Brown Violet Black White...

  • Page 438: Operating Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 439 According to – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the ® corresponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)

  • Page 440: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Strong Cleaning and polishing materials for metal, rubber and plastic Guideline –...
  • Page 441 AUXILIARY SUBSTANCES Lubricant (T625) Guideline – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium 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 442: Special Tools

    SPECIAL TOOLS Bearing puller Art. no.: 15112017000 400037-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58429009000 400073-01 Valve spring mounter Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01...
  • Page 443 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 400110-01 Graduated disc Art. no.: 60029010000 400120-01 Plastigauge measuring strips Art. no.: 60029012000 400122-01 Piston ring mounting tool Art. no.: 60029015000 400123-01 Insert for bearing puller Art. no.: 60029018000 Feature 23… 28 mm (0.91… 1.1 in) 400038-01...
  • Page 444 SPECIAL TOOLS Step bearing tool Art. no.: 60029046028 400136-01 Pliers for spring-loaded band-type clamp Art. no.: 60029057100 400085-01 Multi-tooth wrench socket 10 mm; ½" drive Art. no.: 60029075000 400145-01 Work stand rear Art. no.: 61029055100 500077-01 Work stand adapter Art. no.: 61029055120 700270-01...
  • Page 445 SPECIAL TOOLS Front work stand Art. no.: 61029055300 500078-01 Pressure testing tool Art. no.: 61029094000 400149-01 Engine work stand Art. no.: 61229001000 200306-01 Engine holder Art. no.: 61229002000 200307-01 Clutch holder Art. no.: 61229003000 200308-01...
  • Page 446 SPECIAL TOOLS Mounting sleeve Art. no.: 61229005000 200309-01 Pressure piece Art. no.: 61229008000 200438-01 Extractor Art. no.: 61229010000 200310-01 Press drift Art. no.: 61229013000 200311-01 Engine blocking screw Art. no.: 61229015000 200312-01...
  • Page 447 SPECIAL TOOLS Pressure bell Art. no.: 61229016000 200313-01 Arms for extractor 78029033100 Art. no.: 61229017000 200314-01 Pressure piece Art. no.: 61229018000 200315-01 Extractor Art. no.: 61229020000 200316-01 Release device for timing chain tensioner Art. no.: 61229021000 200317-01...
  • Page 448 SPECIAL TOOLS Hex key bit Art. no.: 61229025000 200318-01 Press drift/press sleeve Art. no.: 61229044000 200319-01 Press sleeve Art. no.: 61229045000 200320-01 Frame support Art. no.: 61229050000 400490-01 Centering pin Art. no.: 61229051000 400491-01...
  • Page 449 SPECIAL TOOLS Floor jack attachment Art. no.: 61229055000 400184-01 Work stand Art. no.: 62529055000 400151-01 Adjustment gauge, control time, cylinder 2 Art. no.: 69129030000 301465-10 Adjustment gauge, control time, cylinder 1 Art. no.: 69129130000 301466-10 Piston pin lock ring insert Art.
  • Page 450 SPECIAL TOOLS Oil pressure testing adapter Art. no.: 75029094000 400169-01 Spark plug wrench Art. no.: 75029172000 400170-01 Puller, 2-arm Art. no.: 78029033100 500166-01 Valve spring mounting device Art. no.: 78029060000 500165-01 Hook wrench Art. no.: T106S 301085-01...
  • Page 451 SPECIAL TOOLS Depth micrometer Art. no.: T107S 300577-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Pressing tool Art. no.: T129 200584-01 Gripping tool Art. no.: T14026S1 200639-10...
  • Page 452 SPECIAL TOOLS Open-end wrench Art. no.: T14032 200640-10 Nitrogen filling tool Art. no.: T170S1 300574-10 Mounting sleeve Art. no.: T313 300578-10 Art. no.: T524 200641-10 Clamping stand Art. no.: T526S 200636-10...
  • Page 453 SPECIAL TOOLS Clamping stand Art. no.: T612S 200638-10...

  • Page 454: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 455: Index

    INDEX torque limiter and idler, installing ....176 INDEX transmission shaft, installing ....164 Accessories .
  • Page 456 INDEX Coolant refilling ....... . . 196 EFI control unit ....... 227 Coolant level activation code, requesting .
  • Page 457 INDEX removing completely ......63 Handlebar height adjusting ....... . . 32 Exhaust system installing .
  • Page 458 INDEX Oil screen Shift lever stub cleaning ....... . 209 adjusting .
  • Page 459 INDEX Tire condition checking ....... . . 78 Trouble code engine control .
  • Page 460 *3206077en* 3206077en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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