KTM 1090 ADVENTURE 2017 Owner's Manual
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KTM 1090 ADVENTURE 2017 Owner's Manual

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OWNER'S MANUAL
2017
1090 Adventure
Art. no. 3213545en

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Summary of Contents for KTM 1090 ADVENTURE 2017

  • Page 1 OWNER'S MANUAL 2017 1090 Adventure Art. no. 3213545en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Fork part number ..........24 TABLE OF CONTENTS MEANS OF REPRESENTATION ........8 Shock absorber article number ......25 Symbols used ............8 CONTROLS..............26 Formats used............9 Clutch lever............26 SAFETY ADVICE............10 Hand brake lever..........26 Use definition - intended use ......
  • Page 6 TABLE OF CONTENTS 6.19 Shift lever ............41 7.10.16 "Fuel Cons" ........... 59 6.20 Foot brake lever ..........42 7.10.17 "Clock/Date" ..........60 6.21 Side stand............42 7.10.18 "Shift Light" ..........60 COMBINATION INSTRUMENT ........43 7.10.19 "Heat Grip" (optional) ........61 Overview ............
  • Page 7 TABLE OF CONTENTS 10.7 Transport ............88 13.14 Checking/correcting the fluid level of the hydraulic clutch..........109 10.8 Refueling ............89 13.15 Checking the play of the steering head bearing ... 110 11 SERVICE SCHEDULE ............ 91 13.16 Removing the bottom triple clamp cover..... 111 11.1 Additional information ........
  • Page 8 TABLE OF CONTENTS 15 WHEELS, TIRES ............140 18 TUNING THE ENGINE..........185 15.1 Removing the front wheel ......140 18.1 "Drive Mod" ............. 185 15.2 Installing the front wheel ......142 18.2 Traction control (TC) ........185 15.3 Removing the rear wheel .......
  • Page 9 TABLE OF CONTENTS 24 SUBSTANCES ............216 25 AUXILIARY SUBSTANCES ........... 219 26 STANDARDS .............. 221 27 INDEX OF SPECIAL TERMS ......... 222 28 LIST OF ABBREVIATIONS..........223 29 LIST OF SYMBOLS............224 29.1 Red symbols............ 224 29.2 Yellow and orange symbols........ 224 29.3 Green and blue symbols........

  • Page 10: Means Of Representation

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

  • Page 11: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 12: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses. Info The motorcycle is only authorized for operation on public roads in the homologated version.

  • Page 13: Degrees Of Risk And Symbols

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

  • Page 14: Safe Operation

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

  • Page 15: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in paren- theses.

  • Page 16: Owner's Manual

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

  • Page 17: Important Notes

    Warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 18: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 20: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) F00685-10...
  • Page 21 VIEW OF VEHICLE Clutch lever ( p. 26) Seat lock ( p. 39) Grab handles ( p. 39) Luggage rack plate ( p. 40) Passenger footrest ( p. 40) Rider footrests ( p. 67) Shift lever ( p. 41) Side stand ( p.

  • Page 22: View Of Vehicle, Rear Right Side (Example)

    VIEW OF VEHICLE View of vehicle, rear right side (example) F00686-10...
  • Page 23 VIEW OF VEHICLE Shock absorber, spring preload setting Combination switch ( p. 27) Filler cap Electric starter button ( p. 31) Emergency OFF switch ( p. 31) Throttle grip ( p. 27) Ignition/steering lock ( p. 32) Hand brake lever ( p.

  • Page 24: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the bottom right of the frame behind the steering head. The chassis number is also shown on the type label. 402294-10 Type label (EU) Type label is affixed to the top left of the frame behind the steering head. 402772-10...

  • Page 25: Key Number

    SERIAL NUMBERS (CN) Type label is affixed the top right of the frame behind the steering head. 0 0 1 402174-10 Key number The key number Code number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 26: Engine Number

    SERIAL NUMBERS Engine number The engine number is stamped on the right side of the engine. 402296-10 Fork part number The fork part number is stamped on the inner side of the fork stub. 402295-10...

  • Page 27: Shock Absorber Article Number

    SERIAL NUMBERS Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber. 402298-10...

  • Page 28: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S00756-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. S00757-10...

  • Page 29: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. S00758-10 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar. Overview of the left combination switch Light switch ( p.

  • Page 30: Light Switch

    CONTROLS 6.4.2 Light switch The light switch is fitted on the combination switch on the left. Possible states Low beam on – Light switch in position . In this position, the low beam and tail light are switched on. High beam on – Push the light switch to position .

  • Page 31: Menu Switch

    CONTROLS 6.4.4 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the matrix display on the combination instrument. Button is the UP button. Button is the DOWN button. Button is the SET button.

  • Page 32: Horn Button

    CONTROLS Info An automatic turn signal switch-off function (ATIR) is available as an optional soft- ware feature. The ATIR function uses a time and distance counter. If the turn signal has been on for at least 10 seconds and 150 meters of riding distance, the turn signal is switched off.

  • Page 33: Switches On The Right Side Of The Handlebar

    CONTROLS Switches on the right side of the handlebar 6.5.1 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started.

  • Page 34: Ignition/Steering Lock

    CONTROLS Ignition/steering lock The ignition/steering lock is located in front of the upper triple clamp. Info The ignition may only be switched on using a black ignition key. With the orange programming key, you can activate or deactivate the black ignition key.

  • Page 35: Locking The Steering

    The black ignition keys are activated when delivered. Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop; they need to be activated for use. Locking the steering Note Danger of damage The parked vehicle can roll away or fall over.

  • Page 36: Unlocking The Steering

    CONTROLS Unlocking the steering – Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove the key. You can now steer the bike again. 400731-01 6.10 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 37 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 38: Closing The Filler Cap

    CONTROLS Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced. – Push down on the filler cap to take pressure off the ignition key. – Turn ignition key clockwise. – Fold open filler cap S00749-10 6.11 Closing the filler cap...

  • Page 39: Fuel Cocks

    CONTROLS – Push down the filler cap and turn the ignition key counterclockwise until the tank lock closes. Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. – Check the filler cap is locked correctly after closing. – Change your clothing in case of fuel spills on them.

  • Page 40: Opening The Storage Compartment

    CONTROLS 6.13 Opening the storage compartment – Press lock in the direction of the arrow and lift the cover at the same time. F00638-10 6.14 Closing the storage compartment – Press cover downward. The lock engages audibly. F00638-11...

  • Page 41: Seat Lock

    CONTROLS 6.15 Seat lock Seat lock is located on the left side of the vehicle. It can be unlocked using the ignition key. F00639-10 6.16 Grab handles The passenger can hold onto grab handles during the trip. F00640-10...

  • Page 42: Luggage Rack Plate

    CONTROLS 6.17 Luggage rack plate The luggage rack plate is located behind the seat. The base plate of a luggage system (optional) can be attached to the luggage rack plate. The luggage rack plate may not be loaded with more than the specified weight. Maximum permissible load 8 kg (18 lb.) on luggage rack plate...

  • Page 43: Shift Lever

    CONTROLS 6.19 Shift lever The shift lever is fitted on the left side of the engine. 402299-10 The gear positions can be seen in the figure. The idle position is between the first and second gears. 402299-11...

  • Page 44: Foot Brake Lever

    CONTROLS 6.20 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. 402301-10 6.21 Side stand The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle.

  • Page 45: Combination Instrument

    COMBINATION INSTRUMENT Overview Matrix display ( p. 44) Tachometer Shift warning light ( p. 47) Segment display Indicator lamps ( p. 45) 402775-10 Activation and test Activation The combination instrument is activated when the ignition is switched on. Info The brightness of the displays is controlled by a brightness sensor in the combina- tion instrument.

  • Page 46: Matrix Display

    COMBINATION INSTRUMENT Matrix display The matrix display is controlled using the menu switch ( p. 29). After the ignition is switched on, the display shows when the next service ( p. 48) is due. If the General warning lamp lights up among the indicator lamps ( p.

  • Page 47: Fuel Level Display

    COMBINATION INSTRUMENT Fuel level display The fuel level display shows the filling level of the fuel tank. Info The fuel level is displayed with a slight delay to prevent the indicator from con- stantly moving while riding. The fuel level display is not updated while the side stand is folded out or the emer- gency off switch is switched off.

  • Page 48: Message On The Matrix Display

    KTM workshop. General message – General message on operating safety. Visit an autho- rized KTM workshop. ABS warning – ABS is not available. Visit an authorized KTM workshop. Traction control – Traction control is not available. Visit an authorized KTM 401850-01 workshop.

  • Page 49: Shift Warning Light

    Battery voltage – The battery voltage is too low. Recharge the battery with a suitable battery charger. Service – A service is due. Contact an authorized KTM workshop. Emergency OFF switch – The emergency OFF switch is off. The messages are displayed in the "Warning" menu.

  • Page 50: Service Display

    COMBINATION INSTRUMENT The shift warning light is con- > "RPM2" tinuously lit ≤ 35 °C (≤ 95 °F) Engine oil temperature "ODO" < 1,000 km (< 620 mi) The shift warning light always 6,500 rpm lights up at service display After the ignition is switched on, the service display appears briefly.

  • Page 51: Matrix Display Menu

    COMBINATION INSTRUMENT 7.10 Matrix display menu 7.10.1 "Favorites" – Press the UP or DOWN button until the "Favorites" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button to select the menu item and activate it with the SET but- ton.

  • Page 52: Trip 2

    COMBINATION INSTRUMENT 7.10.3 "Trip 2" – Press the UP or DOWN button until the "Trip 2" menu appears on the matrix display. "Trip 2" shows the distance since the last reset, such as between two refueling stops. "Trip 2" runs continuously and counts the distance up to 9999. "Ø...

  • Page 53: Set Favorites

    COMBINATION INSTRUMENT 7.10.5 "Set Favorites" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Set Favorites" menu appears on the matrix dis- play. Pressing the SET button opens the menu. – Press the UP or DOWN button to select the menu. Press the SET button to set the menu for quick selection.

  • Page 54: Warning

    COMBINATION INSTRUMENT 7.10.7 "Warning" Condition • Message or warning – Press the UP or DOWN button until the "Warning" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the UP or DOWN button to navigate through the warnings. In the "Warning"...

  • Page 55: Mtc/Abs

    COMBINATION INSTRUMENT 7.10.9 "MTC/ABS" Condition • The vehicle is stationary. Warning Voiding of the government approval for road use and the insurance coverage If the ABS is switched off completely, the vehicle's approval for road use is invali- dated. – Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off completely.
  • Page 56 COMBINATION INSTRUMENT OFFROAD (optional) – reduced homologated performance for better ridability; the traction control allows high slip on the rear wheel...

  • Page 58: 7.10.11 Menu Overview

    COMBINATION INSTRUMENT 7.10.11 Menu overview F00707-01...

  • Page 59: 7.10.12 "Language

    COMBINATION INSTRUMENT "KTM" start screen Menu buttons "Favorites" "Trip 1" "Trip 2" "General Info" "Set Favorites" "Settings" "Warning" (only active if there are messages) "Heating" (optional) "MTC/ABS" "Drive Mod" 7.10.12 "Language" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display.

  • Page 60: 7.10.13 "Distance

    COMBINATION INSTRUMENT 7.10.13 "Distance" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Distance" is highlighted in black on the matrix dis- play.

  • Page 61: 7.10.15 "Pressure

    COMBINATION INSTRUMENT 7.10.15 "Pressure" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Pressure" is highlighted in black on the matrix dis- play.

  • Page 62: 7.10.17 "Clock/Date

    COMBINATION INSTRUMENT 7.10.17 "Clock/Date" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Clock/Date" is highlighted in black on the matrix dis- play.

  • Page 63: Heat Grip" (Optional)

    COMBINATION INSTRUMENT 7.10.19 "Heat Grip" (optional) Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display. Pressing the SET button opens the menu. – Press the UP or DOWN button until "Heat Grip" is highlighted in black on the matrix dis- play.
  • Page 64 COMBINATION INSTRUMENT Warning Danger of accidents When visibility is poor, the daytime running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain.

  • Page 65: Ergonomics

    ERGONOMICS Handlebar position The holes on the handlebar support are placed at a distance of from the center. 3.5 mm (0.138 in) Hole distance The handlebar can be mounted in two different positions. In this way, the handlebar can be mounted in the position that is most comfortable for the rider.
  • Page 66 ERGONOMICS – Remove screws . Remove the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not bend the cables and lines. – Remove screws . Take off the handlebar supports. –...

  • Page 67: Adjusting The Wind Shield

    ERGONOMICS Adjusting the wind shield – Pull the clamping lever in the direction of the arrow. The windshield is unlocked. F00641-10 – Move the wind shield in the required position. F00688-10...

  • Page 68: Adjusting Basic Position Of Clutch Lever

    ERGONOMICS – Push the clamping lever in the direction of the arrow. The windshield is locked. F00641-11 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 69: Adjusting The Basic Position Of The Hand Brake Lever

    ERGONOMICS Adjusting the basic position of the hand brake lever – Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel Info Push the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding.

  • Page 70: Adjusting The Footrests

    ERGONOMICS Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides. – Remove screw The foot brake lever swings up to the stop. F00646-10 – Remove cotter pin with washer – Carefully remove the pin of the rider footrest.
  • Page 71 ERGONOMICS – Remove screws M00883-10 – Adjust the footrest bracket to the desired position. M00884-10 – Mount and tighten screws Guideline Screw, front footrest bracket M8 25 Nm Loctite ® 243™ (18.4 lbf ft) M00883-10...

  • Page 72: Checking The Basic Position Of The Shift Lever

    ERGONOMICS – Mount the rider footrest with spring and pin Pliers for footrest spring (58429083000) – Mount washer and cotter pin M00882-10 – Position the foot brake lever. – Mount and tighten screw Guideline Screw, ball joint of push rod 10 Nm Loctite ®...

  • Page 73: Adjusting The Basic Position Of The Shift Lever

    ERGONOMICS – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in) edge of boot » If the distance does not meet specifications: 0 0 0 A –...

  • Page 74: Adjusting The Basic Position Of The Foot Brake Lever

    ERGONOMICS – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
  • Page 75 ERGONOMICS – Mount and tighten screw Guideline Screw, ball joint of push rod 10 Nm Loctite ® 243™ on foot brake cylinder (7.4 lbf ft) – Attach spring...

  • Page 76: Preparing For Use

    Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling characteristic. – Only use tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened.

  • Page 77: Running In The Engine

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

  • Page 78: Loading The Vehicle

    PREPARING FOR USE – Avoid fully opening the throttle! Info If the maximum engine speed is exceeded before the first service, the shift warning light flashes. Loading the vehicle Warning Danger of accidents Total weight and axle loads influence the handling characteristic. The overall weight consists of: motorcycle ready for operation and with a full tank, driver and passenger with protective clothing and helmet, and luggage.
  • Page 79 PREPARING FOR USE Warning Danger of accidents Luggage which has slipped impairs visibility. If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. – Check that your luggage is fixed properly at regular intervals. Warning Danger of accidents A high payload alters the handling characteristic and increases the stopping distance.

  • Page 80: Riding Instructions

    RIDING INSTRUCTIONS 10.1 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 81: Starting

    RIDING INSTRUCTIONS 10.2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing.

  • Page 82: Starting Off

    RIDING INSTRUCTIONS – Press the electric starter button Info Do not press the electric starter button until the combination instrument func- tion check is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 83 RIDING INSTRUCTIONS Warning Danger of accidents An incorrect ignition key position causes malfunctions. – Do not change the ignition key position while driving. Warning Danger of accidents Adjustments to the vehicle distract attention from traffic activity. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly.
  • Page 84 RIDING INSTRUCTIONS Warning Danger of accidents Total weight and axle loads influence the handling characteristic. The overall weight consists of: motorcycle ready for operation and with a full tank, driver and passenger with protective clothing and helmet, and luggage. – Do not exceed the maximum permissible overall weight or the axle loads. Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic.
  • Page 85 RIDING INSTRUCTIONS Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle.

  • Page 86: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.
  • Page 87 RIDING INSTRUCTIONS Warning Danger of accidents Higher total weight increases the stopping distance. – Take the longer stopping distance into account when carrying a passenger or luggage with you. Warning Danger of accidents Salt on the roads impairs the brake system. – Brake carefully several times to remove salt from the brake linings and the brake discs.

  • Page 88: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents The rear wheel can lock due to the engine braking effect. – Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground. Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. –...
  • Page 89 RIDING INSTRUCTIONS Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. – Park the vehicle on a firm and level surface. –...

  • Page 90: Transport

    RIDING INSTRUCTIONS 10.7 Transport Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. –...

  • Page 91: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 92 RIDING INSTRUCTIONS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open the filler cap. ( p.

  • Page 93: Service Schedule

    15,000 km (9,300 mi) after 1,000 km (620 mi) ○ ● ● ● ● Read out the trouble code memory using the KTM diagnostics tool. ○ ● ● ● ● Check that the electrical system is functioning properly. ○...
  • Page 94 Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Reset the service display using the KTM diagnostic tool.

  • Page 95: Recommended Work

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval 11.3 Recommended work Every four years Every year every 30,000 km (18,600 mi) every 15,000 km (9,300 mi) after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ○ ●...

  • Page 96: Suspension Setting

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.
  • Page 97 SUSPENSION SETTING – Turn adjusting screw counterclockwise all the way. – Turn it clockwise by the number of turns corresponding to the shock absorber type and use. Guideline Spring preload Standard 2 turns Info Turn clockwise to increase the spring preload; turn counterclockwise to reduce F00647-10 the spring preload.

  • Page 98: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 13.1 Raising the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Mount lifting bushings on the swingarm. –...

  • Page 99: Lifting The Motorcycle With The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the motorcycle on the side stand – Remove the lifting bushings from the swingarm. 402029-10 13.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over.

  • Page 100: Taking The Motorcycle From The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. – Attach the front lifting gear with the adapters on the steering stem. Mounting pin (69329965030) Lifting gear, front (61029055500) – Align the front lifting gear with the fork legs. Info F00649-01 Always raise the motorcycle at the rear first.

  • Page 101: Raising The Motorcycle With The Work Stand (Inserted)

    SERVICE WORK ON THE CHASSIS Finishing work – Install the bottom triple clamp cover. ( p. 112) 13.5 Raising the motorcycle with the work stand (inserted) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. –...

  • Page 102: Removing The Motorcycle From The Work Stand (Inserted)

    SERVICE WORK ON THE CHASSIS 13.6 Removing the motorcycle from the work stand (inserted) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Secure the motorcycle against falling over. –...

  • Page 103: Removing The Seat

    SERVICE WORK ON THE CHASSIS 13.7 Removing the seat – Insert the ignition key in the seat lock and turn it clockwise by 45°. – Raise the rear of the seat, pull the seat back, and lift it off. – Remove the ignition key.

  • Page 104: Checking For Chain Dirt

    SERVICE WORK ON THE CHASSIS 13.9 Checking for chain dirt – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 102) 400678-01 13.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...

  • Page 105: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 96) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –...

  • Page 106: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 96) Main work – Shift the transmission to idle – In the area in front of the chain guide, push the chain up and determine the chain ten- sion Info The upper part of the chain...
  • Page 107 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 96) – Check the chain tension. ( p. 103) Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning the adjusting screws left and right.

  • Page 108: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 96) 13.13 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 109 SERVICE WORK ON THE CHASSIS – Shift the transmission to idle – Pull the lower chain section with the specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain rollers on the upper part of the chain. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 110 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear at the recess. Info When the chain sliding guard is new, the rivets are half visible at the bottom edge of the recess. » When the rivets of the chain are no longer visible at the bottom edge of the recess of the chain sliding guard: –...

  • Page 111: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 13.14 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

  • Page 112: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 113: Removing The Bottom Triple Clamp Cover

    SERVICE WORK ON THE CHASSIS Main work – Place a load on the rear of the vehicle. The front wheel is not in contact with the ground. – Move the handlebar to the straight-ahead position. Move the fork legs back and forth in the direction of travel.

  • Page 114: Installing The Bottom Triple Clamp Cover

    SERVICE WORK ON THE CHASSIS – Disconnect plugs of the horn. – Detach temperature sensor – Remove the triple clamp cover. F00655-10 13.17 Installing the bottom triple clamp cover – Plug in connectors of the horn. – Attach temperature sensor F00655-11...

  • Page 115: Removing The Front Side Cover

    SERVICE WORK ON THE CHASSIS – Position the triple clamp cover – Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) F00654-11 13.18 Removing the front side cover – Remove screw F00656-10...

  • Page 116: Installing The Front Side Cover

    SERVICE WORK ON THE CHASSIS – Remove screws – Remove side cover – Repeat the operation on the opposite side. F00657-10 13.19 Installing the front side cover – Position the side cover in the area under the tank cover. F00658-10...
  • Page 117 SERVICE WORK ON THE CHASSIS – Attach catch of the side cover to bracket and position on the fuel tank. – Position the holding lug in the drill hole. F00659-10 – Mount and tighten screw Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) F00656-11 –...

  • Page 118: Removing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS 13.20 Removing the mask spoiler Preparatory work – Remove the seat. ( p. 101) – Remove the front side cover. ( p. 113) – Remove the tank cover. ( p. 123) Main work – Remove screw F00660-10 –...
  • Page 119 SERVICE WORK ON THE CHASSIS – Loosen holding lug from the inside cover. F00692-10 – Remove the mask spoiler laterally from the supports. F00691-01 – Remove catch upward from the bracket Info Pay attention to the turn signal cable. F00663-10...

  • Page 120: Installing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS – Disconnect plug-in connector – Remove the mask spoiler with the turn signal. – Repeat the operation on the opposite side. F00664-10 13.21 Installing the mask spoiler Main work – Connect plug-in connector F00664-11...
  • Page 121 SERVICE WORK ON THE CHASSIS – Position the catch in the bracket Info Ensure that the turn signal cable is placed correctly. F00663-11 – Press the mask spoiler laterally into the supports. F00691-02 – Position the holding lug in the drill hole. F00692-11...
  • Page 122 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) F00661-11 – Mount and tighten screw Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) – Repeat the operation on the opposite side. F00660-11 Finishing work –...

  • Page 123: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS 13.22 Removing the front fender – Open holder and detach the brake lines and cable. – Remove screws – Remove the fender in a forward direction. Info Pay attention to the brake lines and the cable. F00665-10 13.23 Installing the front fender...

  • Page 124: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 13.24 Cleaning the dust boots of the fork legs Preparatory work – Remove the front fender. ( p. 121) Main work – Push dust boot of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots.

  • Page 125: Removing The Tank Cover

    SERVICE WORK ON THE CHASSIS 13.25 Removing the tank cover Preparatory work – Remove the seat. ( p. 101) – Remove the front side cover. ( p. 113) Main work – Remove screw – Remove screw F00666-10 – Remove screw –...
  • Page 126 SERVICE WORK ON THE CHASSIS – Remove screw F00668-10 – Raise the tank cover at the rear and remove it in a forward direction. F00662-01...

  • Page 127: Installing The Tank Cover

    SERVICE WORK ON THE CHASSIS 13.26 Installing the tank cover Main work – Position the tank cover. The catch engages under the tank Info Pay attention to the sealing lip and the bleeder hose. M00923-10 – Mount and tighten screw Guideline Screw, cover part 3.5 Nm...
  • Page 128 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, cover part 6 Nm (4.4 lbf ft) – Mount and tighten screw Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) F00666-11 – Mount and tighten screw Guideline Screw, cover part 6 Nm (4.4 lbf ft) –...

  • Page 129: Removing The Wind Shield

    SERVICE WORK ON THE CHASSIS 13.27 Removing the wind shield – Remove screws and wind shield F00669-10 13.28 Installing the wind shield – Position wind shield – Mount and tighten screws Guideline Screw, wind shield 3.5 Nm (2.58 lbf ft) F00669-11...

  • Page 130: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS 13.29 Removing the engine guard – Remove screws with bushings and engine guard F00670-11 13.30 Installing the engine guard – Position engine guard , mount screws with bushings and tighten. Guideline Screw, engine guard 10 Nm (7.4 lbf ft) F00670-10...

  • Page 131: Brake System

    – Only use spare parts on the brake system which have been approved and recom- mended by KTM. – Only use tires/wheels approved by KTM with the corresponding speed index. – Maintain the specified tire air pressure. – Service work and repairs must be performed professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 132 BRAKE SYSTEM Warning Danger of accidents Driving aids can only prevent a rollover within the physical limi- tations. It is not always possible to compensate for extreme riding situations, for exam- ple with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.

  • Page 133: Checking The Brake Discs

    Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each brake...

  • Page 134: Checking The Brake Fluid Level Of The Front Brake

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.

  • Page 135: Adding Front Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.

  • Page 136: Checking The Front Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 14.5 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 137: Checking The Rear Brake Fluid Level

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

  • Page 138: Adding Rear Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 139 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 140: Checking The Rear Brake Linings

    Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.
  • Page 141 BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »...

  • Page 142: Wheels, Tires

    WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 96) – Remove the bottom triple clamp cover. ( p. 111) – Lift the motorcycle with the front lifting gear. ( p.
  • Page 143 WHEELS, TIRES – Loosen screw by several rotations. – Release screws – Press on screw to push the wheel spindle out the axle clamp. – Remove screw Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake discs are not dam- M00916-10 aged.

  • Page 144: Installing The Front Wheel

    WHEELS, TIRES 15.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...
  • Page 145 WHEELS, TIRES Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. – Clean and grease screw and wheel spindle Long-life grease ( p.
  • Page 146 WHEELS, TIRES Guideline Screw, front brake caliper 45 Nm Loctite ® 243™ (33.2 lbf ft) – Remove the locking piece of the hand brake lever. – Position wheel speed sensor in the drill hole. – Mount and tighten screw Guideline Screw, wheel speed sensor, front 10 Nm (7.4 lbf ft) –...

  • Page 147: Removing The Rear Wheel

    WHEELS, TIRES 15.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 96) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- tons.
  • Page 148 WHEELS, TIRES – Remove nut . Remove chain adjuster F00716-10 – Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Take the chain off of the rear sprocket and place it on chain sprocket guard Warning Danger of accidents Reduced braking effect caused by damaged brake discs.

  • Page 149: Installing The Rear Wheel

    WHEELS, TIRES 15.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
  • Page 150 WHEELS, TIRES – Mount wheel spindle but do not push it in all the way. – Push the rear wheel as far forward as possible and place the chain on the rear sprocket. F00713-10 – Push the wheel spindle in all the way and mount chain adjuster and nut Info Mount chain adjusters...

  • Page 151: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – Position wheel speed sensor in the drill hole. – Mount and tighten screw Guideline Screw, wheel speed sensor, rear 10 Nm (7.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
  • Page 152 WHEELS, TIRES Main work – Check the rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: – Change all rubber dampers in the rear hub. M00937-10 –...

  • Page 153: Checking The Tire Condition

    Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.

  • Page 154: Checking The Tire Air Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regard- less of the actual state of wear.
  • Page 155 WHEELS, TIRES – Remove the dust cap. – Check the tire air pressure when the tires are cold. Tire air pressure, solo/with passenger/full payload Front: with cold tires 2.4 bar (35 psi) Rear: with cold tires 2.9 bar (42 psi) »...

  • Page 156: Electrical System

    ELECTRICAL SYSTEM 16.1 Daytime running light Warning Danger of accidents When visibility is poor, the daytime running light is not a sub- stitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain. –...

  • Page 157: Removing The Battery

    ELECTRICAL SYSTEM 16.2 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 158 ELECTRICAL SYSTEM Main work – Pull locking mechanism in the direction of the arrow. – Fold open cover D02869-10 – Disconnect negative cable from the battery. – Disconnect positive cable from the battery. – Take the battery and battery case out of the battery compartment.

  • Page 159: Installing The Battery

    ELECTRICAL SYSTEM 16.3 Installing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 160 ELECTRICAL SYSTEM – Position the negative cable and mount and tighten the screw. Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) – Close the cover and push down slightly. The cover engages with an audible click. F00697-10 Finishing work –...

  • Page 161: Recharging The Battery

    ELECTRICAL SYSTEM 16.4 Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 162 The battery is maintenance-free, i.e., the acid level does not have to be checked. If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage may damage electronic components. Charge the battery according to the instructions on the battery housing.
  • Page 163 ELECTRICAL SYSTEM – Disconnect negative cable of the battery to avoid damage to the motorcycle's elec- tronics. D02871-10 – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) Info You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator.
  • Page 164 ELECTRICAL SYSTEM – Connect both negative cables with the battery. Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) D02871-10 – Close cover and push down slightly. The cover engages with an audible click. F00697-10 Finishing work – Mount the seat. ( p.

  • Page 165: Changing The Main Fuse

    ELECTRICAL SYSTEM 16.5 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 166 ELECTRICAL SYSTEM – Take off protection caps K00696-10 – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. The main fuse protects all power consumers of the vehicle. –...

  • Page 167: Changing The Fuses In The Fuse Box

    ELECTRICAL SYSTEM – Position rear fairing Heat protector is correctly positioned. – Mount and tighten screw Guideline Rear fairing screw M5x12 3.5 Nm (2.58 lbf ft) – Mount and tighten screw Guideline K00694-10 Rear fairing screw M5x17 3.5 Nm (2.58 lbf ft) Finishing work –...
  • Page 168 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 101) Main work – Open fuse box cover F00698-10 – Check the fuses. Info A defective fuse is indicated by a burned-out fuse wire –...

  • Page 169: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Fuse (58011109110) ( p. 210) Fuse (58011109115) ( p. 210) Fuse (58011109125) ( p. 210) Insert a spare fuse so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work –...
  • Page 170 ELECTRICAL SYSTEM Main work – Remove screws – Remove the headlight mask forward. F00675-10 – Disconnect plug-in connector – Place the headlight mask onto a soft cloth so that the headlight is not damaged. F00676-10...

  • Page 171: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 16.8 Installing the headlight mask with the headlight Main work – Connect plug-in connector of the headlight. – Check that the lighting is functioning properly. – Position the headlight mask. F00676-11 – Mount and tighten screws Guideline Screw, headlight 5 Nm (3.7 lbf ft) F00675-11 Finishing work...

  • Page 172: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM 16.9 Changing the low beam bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the lamp will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 173: Changing The High Beam Bulb

    ELECTRICAL SYSTEM – Plug connector into the new headlight bulb. Low beam (H11/socket PGJ19-2) ( p. 210) – Position headlight bulb into the bulb socket and turn it all the way clockwise. The headlight bulb is locked into the bulb socket. F00678-10 Finishing work –...
  • Page 174 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 101) – Remove the front side cover. ( p. 113) – Remove the tank cover. ( p. 123) – Remove the mask spoiler.

  • Page 175: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM Finishing work – Install the headlight mask with the headlight. ( p. 169) – Install the wind shield. ( p. 127) – Install the mask spoiler. p. 118) – Install the tank cover. ( p. 125) – Install the front side cover. ( p.

  • Page 176: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Check that the turn signal is functioning properly. – Position the diffuser. Info Insert catch into recess – Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly. 16.12 Checking the headlight setting –...

  • Page 177: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 16.13 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 174) – Remove the bottom triple clamp cover. ( p. 111) Main work – Turn adjusting screw to adjust the headlight range. Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.

  • Page 178: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM 16.14 Activating/deactivating the ignition key Info The orange programming key must only be used for activating and deactivating! If a black ignition key is lost or needs to be replaced, the individual black ignition keys need to be enabled or disabled using the orange programming key.
  • Page 179 ELECTRICAL SYSTEM – Switch off the ignition by turning the black ignition key to the position OFF – Remove the black ignition key. – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position The immobilizer indicator lamp flashes according to the number of func- tional black ignition keys including the orange programming key.
  • Page 180 ELECTRICAL SYSTEM – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position Immobilizer indicator lamp lights up. – Switch off the ignition by turning the orange programming key to the OFF position –...
  • Page 181 ELECTRICAL SYSTEM – If the last black ignition key was activated, insert the orange programming key into the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position The immobilizer indicator lamp flashes according to the number of func- tional black ignition keys including the orange programming key.
  • Page 182 ELECTRICAL SYSTEM Info After the fourth black ignition key has been activated, programming is fin- ished.

  • Page 183: Cooling System

    COOLING SYSTEM 17.1 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at oper- ating temperature.

  • Page 184: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM – Check the coolant level in the compensating tank The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! –...
  • Page 185 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 186 COOLING SYSTEM – Add coolant until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX. Coolant ( p. 216) – Mount the cover of the compensating tank. F00683-01 Finishing work – Install the front side cover. ( p.

  • Page 187: Tuning The Engine

    TUNING THE ENGINE 18.1 "Drive Mod" Possible states SPORT – Homologated performance with very direct response; the traction control • allows greater slip on the rear wheel STREET – Homologated performance with balanced response; the traction control • allows normal slip on the rear wheel RAIN –...
  • Page 188 TUNING THE ENGINE Info When traction control is active, the TC lamp flashes. When traction control is switched off, the TC lamp is lit.

  • Page 189: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 19.1 Checking the engine oil level Info Oil consumption depends on the riding style and the operating conditions. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...

  • Page 190: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 19.2 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
  • Page 191 SERVICE WORK ON THE ENGINE – Remove screws . Remove oil filter cover with the O-ring. F00701-11 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. F00702-10 –...
  • Page 192 SERVICE WORK ON THE ENGINE – Mount and tighten screws Guideline Remaining engine screws 6 Nm (4.4 lbf ft) F00701-12 – Thoroughly clean magnets and oil screens of the oil drain plugs. 100773-12 – Mount and tighten oil drain plugs with the magnets, O-rings, and oil screens.
  • Page 193 SERVICE WORK ON THE ENGINE – Add the oil quantity in two separate operations. Engine oil 3.60 l (3.8 qt.) Outside Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 217) Outside Engine oil (SAE temperature: 5W/40) ( p.

  • Page 194: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the screw plug and add the remaining engine oil to upper marking on the engine oil level viewer. – Mount the screw plug. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 195 Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 217) F00695-10 Info In order to achieve optimal engine performance, it is not advisable to mix differ- ent engine oils. KTM recommends changing the engine oil. – Mount the screw plug.
  • Page 196 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 197: Cleaning, Care

    CLEANING, CARE 20.1 Cleaning motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 198 CLEANING, CARE – Close off the exhaust system to keep water from entering. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p.

  • Page 199: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE – Treat bare metal parts (except for brake discs and exhaust system) with corrosion inhibitor. Preserving materials for paints, metal and rubber ( p. 220) – Treat the painted parts with a mild paint polish. Perfect Finish and high gloss polish for paints ( p.
  • Page 200 CLEANING, CARE – Clean the motorcycle. ( p. 195) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.

  • Page 201: Storage

    STORAGE 21.1 Storage Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload).

  • Page 202: Preparing For Use After Storage

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

  • Page 203: Troubleshooting

    Recharge the battery. p. 159) – Check the quiescent current. – Safety start system is faulty Read out the fault memory using the KTM diag- nostics tool. – ICU is not enabled Activate the ICU. – CAN bus communication error Read out the fault memory using the KTM diag- nostics tool.
  • Page 204 Faults Possible cause Action – Engine turns but does not start Fault in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Fuel quality is insufficient Add suitable fuel. – Engine dies during the trip Lack of fuel Refuel.

  • Page 205: Technical Data

    TECHNICAL DATA 23.1 Engine Design 2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled Displacement 1,050 cm³ (64.08 cu in) Stroke 63 mm (2.48 in) Bore 103 mm (4.06 in) Compression ratio 13.0:1 Idle speed 1,300… 1,500 rpm Control DOHC, 4 valves per cylinder, chain-driven Valve - valve plate diameter Intake 42 mm (1.65 in)

  • Page 206: Engine Tightening Torques

    TECHNICAL DATA 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug Inside spark plug NGK LKAR9BI‑10...
  • Page 207 TECHNICAL DATA Screw, bearing shells retaining bracket 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, engine oil level viewer 4 Nm (3 lbf ft) Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, pulse generator 6 Nm (4.4 lbf ft) –...
  • Page 208 TECHNICAL DATA – Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite ® 243™ – Stud, chain shaft 8 Nm (5.9 lbf ft) Loctite ® 243™ Nozzle 100 M6x0.75 4 Nm (3 lbf ft) –...
  • Page 209 TECHNICAL DATA – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) – Spark plug M10x1 11 Nm (8.1 lbf ft) Cylinder head screw M11x1.5...

  • Page 210: Capacities

    TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Outside temperature: ≥ 0 °C Engine oil 3.60 l (3.8 qt.) Engine oil (SAE 10W/50) (≥ 32 °F) p. 217) Outside temperature: < 0 °C Engine oil (SAE 5W/40) (< 32 °F) p. 217) 23.3.2 Coolant Coolant...
  • Page 211 TECHNICAL DATA Front Double disc brake with radially mounted four-pot brake calipers, floating brake discs Rear Single disc brake with dual-piston brake caliper, floating brake disc Brake discs - diameter Front 320 mm (12.6 in) Rear 267 mm (10.51 in) Brake discs - wear limit Front 4 mm (0.16 in)

  • Page 212: Electrical System

    TECHNICAL DATA 23.5 Electrical system Battery YTZ14S Battery voltage: 12 V Nominal capacity: 11.2 Ah maintenance-free Fuse 58011109110 10 A Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Low beam H11/socket PGJ19-2 12 V 55 W High beam H11/socket PGJ19-2 12 V...

  • Page 213: Tires

    110/80 R 19 M/C 59V TL 150/70 R 17 M/C 69V TL Metzeler Tourance NEXT Metzeler Tourance NEXT The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 05.18.6O.08...

  • Page 214: Chassis Tightening Torques

    TECHNICAL DATA Standard 2 turns Spring preload Standard 10 mm (0.39 in) Spring rate Medium (standard) 170 N/mm (971 lb/in) Spring length 205 mm (8.07 in) Static sag 25 mm (0.98 in) Fitted length 402 mm (15.83 in) Shock absorber fluid ( p.
  • Page 215 TECHNICAL DATA – Screw, cover part 3.5 Nm (2.58 lbf ft) – Screw, filler cap 3 Nm (2.2 lbf ft) Screw, foot brake lever stub 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, fuel level sensor 3 Nm (2.2 lbf ft) –...
  • Page 216 TECHNICAL DATA – Screw, fuel tank 10 Nm (7.4 lbf ft) – Screw, fuel tap 6 Nm (4.4 lbf ft) – Screw, headlight 5 Nm (3.7 lbf ft) – Screw, lower rear part 6 Nm (4.4 lbf ft) Screw, magnetic holder on side stand 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 217 TECHNICAL DATA Screw, suitcase hook 20 Nm (14.8 lbf ft) Loctite ® 243™ – Screw, top triple clamp 15 Nm (11.1 lbf ft) – Remaining chassis nuts 45 Nm (33.2 lbf ft) – Remaining chassis screws 45 Nm (33.2 lbf ft) Screw, front brake caliper 45 Nm (33.2 lbf ft) Loctite...

  • Page 218: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 219 SUBSTANCES Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants. Recommended supplier Motorex ® – COOLANT M3.0 Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA ( p. 221) – SAE ( p. 221) (SAE 10W/50) Guideline –...
  • Page 220 SUBSTANCES Recommended supplier Motorex ® – Power Synt 4T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 221) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding proper- ties.

  • Page 221: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
  • Page 222 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 223: Standards

    STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifica- tion.

  • Page 224: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces ATIR Automatic Turn Indicator Reset Software, which automatically switches the indicator off according to a time or travel distance counter Daytime Running Light Light, which enhances the visibility of the vehicle during the day but is not focused, and in contrast to low beam does not illuminate...

  • Page 225: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 226: List Of Symbols

    LIST OF SYMBOLS 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low. 29.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention.
  • Page 227 LIST OF SYMBOLS The left turn signal lamp flashes green with a steady rhythmic flash – The left turn signal is switched on. The idle indicator lamp lights up green – The transmission is in idle. The right turn signal lamp flashes green with a steady rhythmic flash – The right turn signal is switched on.

  • Page 228: Index

    INDEX INDEX Capacity ABS ........129 coolant .
  • Page 229 INDEX "Heat Grip" ........61 Emergency OFF switch ......31 "Heating"...
  • Page 230 INDEX Fork part number ....... . 24 Headlight mask with headlight installing .
  • Page 231 INDEX removing ........116 Protective clothing ....... 13 Matrix display menu .
  • Page 232 INDEX Shifting ........80 Shock absorber Tank cover rebound damping, adjusting .
  • Page 233 INDEX Turn signal bulb changing ........173 Turn signal switch .
  • Page 234 *3213545en* 3213545en 10/2016 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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