KTM 1090 Adventure R Owner's Manual
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KTM 1090 Adventure R Owner's Manual

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OWNER'S MANUAL
2018
1090 Adventure R
Art. no. 3213756en

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Summary of Contents for KTM 1090 Adventure R

  • Page 1 OWNER'S MANUAL 2018 1090 Adventure R Art. no. 3213756en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy riding this motorcycle! Please enter the serial numbers of your vehicle below.
  • 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 assur- ance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS VIEW OF VEHICLE ........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ....10 View of vehicle, front left (example) ... 22 Symbols used ........10 View of vehicle, rear right Formats used........11 (example)........24 SAFETY ADVICE.......... 12 SERIAL NUMBERS ........
  • Page 6 TABLE OF CONTENTS Switches on the right side of the Segment display ......53 handlebar........36 Fuel level display ......54 6.5.1 Emergency OFF switch ....36 Indicator lamps........ 55 6.5.2 Electric starter button ....36 Message on the matrix display... 57 Ignition/steering lock ......
  • Page 7 TABLE OF CONTENTS 7.10.20 "DRL" ......... 74 10 RIDING INSTRUCTIONS......94 ERGONOMICS ..........76 10.1 Checks and maintenance measures when preparing for use ..... 94 Handlebar position......76 10.2 Starting the vehicle ......95 Adjusting the handlebar position ..76 10.3 Starting off........
  • Page 8 TABLE OF CONTENTS 12.5 Compression damping of the shock 13.7 Removing the seat ......133 absorber........120 13.8 Mounting the seat ......133 12.6 Adjusting the low-speed 13.9 Checking for chain dirt ....134 compression damping of the shock 13.10 Cleaning the chain ......134 absorber........
  • Page 9 TABLE OF CONTENTS 13.27 Removing the wind shield ....164 15.6 Checking the tire condition ..... 200 13.28 Installing the wind shield....164 15.7 Checking the tire air pressure..202 13.29 Removing the engine guard..... 165 15.8 Checking spoke tension ....203 13.30 Installing the engine guard .....
  • Page 10 TABLE OF CONTENTS 16.17 ACC1 and ACC2 rear ...... 240 22 TROUBLESHOOTING ........ 265 17 COOLING SYSTEM ........241 23 TECHNICAL DATA........268 17.1 Checking the coolant level in the 23.1 Engine .......... 268 compensating tank......241 23.2 Engine tightening torques ....270 17.2 Correcting the coolant level in the 23.3...
  • Page 11 TABLE OF CONTENTS 29.2 Yellow and orange symbols....296 29.3 Green and blue symbols....297 INDEX ............. 298...

  • Page 12: 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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 13: Formats Used

    MEANS OF REPRESENTATION 1 Indicates a voltage measurement. Indicates a current measurement. Indicates the end of an activity, including potential rework. Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name ®...

  • Page 14: Safety Advice

    2 SAFETY ADVICE Use definition – intended use The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle ter- rain (unpaved roads). This vehicle is not suitable for use on race tracks. Info This vehicle is only authorized for operation on public roads in its homologated version.

  • Page 15: Degrees Of Risk And Symbols

    SAFETY ADVICE 2 Info Various information and warning labels are attached in prominent locations on the model described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the...

  • Page 16: Tampering Warning

    2 SAFETY ADVICE Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any...
  • Page 17 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 18: 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.

  • Page 19: Environment

    Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

  • Page 20: Important Notes

    3 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.

  • Page 21: 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.
  • Page 22 3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...
  • Page 23 3 IMPORTANT NOTES...

  • Page 24: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00220-10...
  • Page 25 VIEW OF VEHICLE 4 Clutch lever ( p. 30) Grab handles ( p. 46) Luggage rack plate ( p. 46) Passenger footrest ( p. 48) Seat lock ( p. 45) Rider footrests ( p. 81) Shift lever ( p. 48) Side stand ( p.

  • Page 26: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) A00218-10...
  • Page 27 VIEW OF VEHICLE 4 Filler cap Combination switch ( p. 31) Fork compression adjustment Electric starter button ( p. 36) Emergency OFF switch ( p. 36) Fork rebound adjustment Hand brake lever ( p. 30) Storage compartment Cooling system compensating tank Foot brake lever ( p.

  • Page 28: Serial Numbers

    5 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.

  • Page 29: Key Number

    SERIAL NUMBERS 5 (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 30: Engine Number

    5 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 31: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber. 402339-10...

  • Page 32: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M00546-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 33: Throttle Grip

    CONTROLS 6 Throttle grip The throttle grip is fitted on the right side of the handlebar. S01749-11 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.

  • Page 34: Light Switch

    6 CONTROLS Overview of the left combination switch Light switch ( p. 32) Hazard warning flasher switch ( p. 33) Menu switch ( p. 34) Turn signal switch ( p. 34) Horn button ( p. 35) M00547-10 6.4.2 Light switch The light switch is fitted on the combination switch on the left.

  • Page 35: Hazard Warning Flasher Switch

    CONTROLS 6 6.4.3 Hazard warning flasher switch The hazard warning flasher switch is fitted on the combination switch on the left. The hazard warning flasher is used to indicate emergency situa- tions. Info The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 60 seconds after the ignition is switched off.

  • Page 36: Menu Switch

    6 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 37: Horn Button

    CONTROLS 6 Info An automatic turn signal switch-off function (ATIR) is avail- able as an optional software 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 38: Switches On The Right Side Of The Handlebar

    6 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 igni- tion circuit is interrupted, a running engine stops, and a non-running engine cannot be started.

  • Page 39: Ignition/Steering Lock

    CONTROLS 6 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. S01751-10 Possible states Ignition off OFF –...

  • Page 40: Immobilizer

    A lost black ignition key must be deactivated to prevent unautho- rized persons from operating the vehicle. 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.

  • Page 41: Locking The Steering

    CONTROLS 6 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar all the way to the left. –...

  • Page 42: Unlocking The Steering

    6 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 43 CONTROLS 6 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 44: Closing The Filler Cap

    6 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 igni- tion key. – Turn ignition key clockwise. – Fold open filler cap S01753-10 6.11 Closing the filler cap...
  • Page 45 CONTROLS 6 – Push down the filler cap and turn the ignition key counter- clockwise 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 clos- ing.

  • Page 46: Fuel Cocks

    6 CONTROLS 6.12 Fuel cocks A fuel cock is located on each side of the fuel tank. Info The fuel cocks must always be open during operation. The fuel cocks are only closed to remove the fuel tank. Possible states Fuel cocks are closed –...

  • Page 47: Closing The Storage Compartment

    CONTROLS 6 6.14 Closing the storage compartment – Press cover downward. The lock engages audibly. S01757-11 6.15 Seat lock The seat lock is located on the left side of the vehicle. It can be unlocked using the ignition key. S01764-10...

  • Page 48: Grab Handles

    6 CONTROLS 6.16 Grab handles The passenger can hold onto grab handles during the trip. S01765-10 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.

  • Page 49: Case Holders

    A case system (optional) can be attached on the case holders. Use case systems approved and/or recommended by KTM. Observe the specifications in the enclosed KTM PowerParts fitting instructions. Info The use of other case systems is not recommended.

  • Page 50: Passenger Footrest

    6 CONTROLS 6.19 Passenger footrest The passenger footrests are foldable. Possible states Passenger footrest folded in – For operation without a passen- • ger. Passenger footrest folded out – For operation with a passen- • ger. S01767-10 6.20 Shift lever The shift lever is fitted on the left side of the engine.

  • Page 51: Foot Brake Lever

    CONTROLS 6 The gear positions can be seen in the figure. The idle position is between the first and second gears. 402299-11 6.21 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...

  • Page 52: Side Stand

    6 CONTROLS 6.22 Side stand Side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system. See the instructions in the "Stopping, parking"...

  • Page 53: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Overview Matrix display ( p. 53) Tachometer Shift warning light ( p. 59) Segment display Indicator lamps ( p. 55) 402341-10 Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segment display, the indicator lamps, and the tachometer are briefly activated for a function test.
  • Page 54 (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop. The oil pressure warning lamp always lights up as long as the engine is not running. If the engine is running and the...

  • Page 55: Matrix Display

    COMBINATION INSTRUMENT 7 Matrix display The matrix display is controlled using the menu switch ( p. 34). After the ignition is switched on, the display shows when the next service ( p. 60) is due. If among the indicator lamps ( p.

  • Page 56: Fuel Level Display

    7 COMBINATION INSTRUMENT Ice warning 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 constantly moving while riding. The fuel level display is not updated while the side stand is folded out or the emergency off switch is switched off.

  • Page 57: Indicator Lamps

    402343-01 to endanger yourself or other road users in the process) and contact an authorized KTM workshop. The oil pressure warning lamp always lights up as long as the engine is not running. If the engine is running and the...
  • Page 58 7 COMBINATION INSTRUMENT 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. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine.

  • Page 59: Message On The Matrix Display

    Message on the matrix display Possible states Engine malfunction – The engine control unit has detected an error. Visit an authorized KTM workshop. General message – General message on operating safety. Visit an authorized KTM workshop. ABS warning – ABS is not available. Visit an autho- rized KTM workshop.
  • Page 60 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.

  • Page 61: Shift Warning Light

    COMBINATION INSTRUMENT 7 Shift warning light The shift warning light flashes or lights up when the transmission should be shifted. In the "Shift Light" menu, the engine speed for the shift warning light can be set. The shift warning light flashes over "RPM1" and lights up continuously over "RPM2".

  • Page 62: Service Display

    7 COMBINATION INSTRUMENT service display After the ignition is switched on, the service display appears briefly. The service intervals depend on the distance traveled or the elapsed time. The event that occurs first is given priority. The exact service intervals can be found in the service schedule. S01595-01 7.10 Matrix display menu...

  • Page 63: Trip 1

    COMBINATION INSTRUMENT 7 In the "Set Favorites" menu, the "Favorites" menu can be config- ured. 7.10.2 "Trip 1" – Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display. "Trip 1" shows the distance since the last reset, such as between two refueling stops.

  • Page 64: Trip 2

    7 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.

  • Page 65: General Info

    COMBINATION INSTRUMENT 7 7.10.4 "General Info" – Press the UP or DOWN button until the "General Info" menu appears on the matrix display. "Air Temp" displays the ambient air temperature. "Date" displays the date. "ODO" displays the total distance covered. "Battery"...

  • Page 66: Settings

    7 COMBINATION INSTRUMENT 7.10.6 "Settings" 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. Settings for units or various values are made in the "Settings" menu.

  • Page 67: Heating" (Optional)

    COMBINATION INSTRUMENT 7 7.10.8 "Heating" (optional) – Press UP or DOWN button until the "Heating" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the SET button to select a heating level or to switch off the heated grips.

  • Page 68: Drive Mod

    7 COMBINATION INSTRUMENT – Press the UP or DOWN button until the "MTC/ABS" menu appears on the matrix display. In the "MTC/ABS" menu, the traction control "TC" and the "ABS" can be switched off. In "ABS Mode", a choice can be made between "Road" and "Offroad".
  • Page 69 COMBINATION INSTRUMENT 7 STREET – homologated performance with balanced response; the traction control allows normal slip on the rear wheel RAIN – reduced homologated performance for better rid- ability; the traction control allows normal slip on the rear wheel OFFROAD – reduced homologated performance for better ridability;...

  • Page 70: Menu Overview

    7 COMBINATION INSTRUMENT 7.10.11 menu overview F00707-01...

  • Page 71: Language

    COMBINATION INSTRUMENT 7 "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 72: Distance

    7 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 display.

  • Page 73: Pressure

    COMBINATION INSTRUMENT 7 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 display.

  • Page 74: Clock/Date

    7 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 display.

  • Page 75: Heat Grip

    COMBINATION INSTRUMENT 7 – Press the UP or DOWN button to select the function. Use the SET button to set the engine speed for the shift warning light. When the engine speed reaches "RPM 1", the shift warning light flashes. When the engine speed reaches "RPM 2", the shift warning light lights up continuously.

  • Page 76: Drl

    7 COMBINATION INSTRUMENT 7.10.20 "DRL" 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. Warning Danger of accidents When visibility is poor, the day- time running light is not a substitute for the low beam.
  • Page 77 COMBINATION INSTRUMENT 7 – Press the UP or DOWN button until "DRL" is highlighted in black on the matrix display. Pressing the SET button again switches the daytime running light on or off. Switch the daytime running light on or off.

  • Page 78: Ergonomics

    8 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 79 ERGONOMICS 8 – 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 80: Adjusting The Wind Shield

    8 ERGONOMICS Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the gap widths are even. Adjusting the wind shield – Pull the clamping lever in the direction of the arrow. The windshield is unlocked. S01768-10...
  • Page 81 ERGONOMICS 8 – Move the wind shield in the required position. S01769-10 – Push the clamping lever in the direction of the arrow. The windshield is locked. S01768-11...

  • Page 82: Adjusting Basic Position Of Clutch Lever

    8 ERGONOMICS 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. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 83: Adjusting The Basic Position Of The Hand Brake Lever

    ERGONOMICS 8 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 adjust- ing wheel.

  • Page 84: Adjusting The Footrests

    8 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. M00622-10 – Remove cotter pin with washer –...
  • Page 85 ERGONOMICS 8 – Remove screws M00641-10 – Adjust the footrest bracket to the desired position. M00623-01...
  • Page 86 8 ERGONOMICS – Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ footrest bracket M00641-10 – Mount the rider footrest with spring and pin Footrest spring plier (58429083000) – Mount washer and cotter pin M00642-10...

  • Page 87: Checking The Basic Position Of The Shift Lever

    ERGONOMICS 8 – Position the foot brake lever. – Mount and tighten screw Guideline Screw, ball joint 10 Nm (7.4 lbf ft) Loctite ® 243™ of push rod on foot brake cylin- M00622-10 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the driver's boot when in the basic position.

  • Page 88: Adjusting The Basic Position Of The Shift Lever

    8 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 10 … 20 mm (0.39 … and upper edge of boot 0.79 in) 0 0 0 A »...
  • Page 89 ERGONOMICS 8 – 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 0 0 A other vehicle components during the shift procedure.

  • Page 90: Adjusting The Basic Position Of The Foot Brake Lever

    8 ERGONOMICS 8.10 Adjusting the basic position of the foot brake lever – Disconnect spring – Loosen nut – Remove screw – To adjust the basic position of the foot brake lever to individ- ual requirements, turn ball joint accordingly. Info The range of adjustment is limited.

  • Page 91: Preparing For Use 9

    Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel. Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index.
  • Page 92 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 93: Running In The Engine

    PREPARING FOR USE 9 – Run the engine in. ( p. 91) Running in the engine – During the running-in phase, do not exceed the specified engine speed. Guideline Maximum engine speed During the first: 1,000 km (620 mi) 6,500 rpm After the first: 1,000 km (620 mi) 10,050 rpm –...
  • Page 94 9 PREPARING FOR USE Warning Danger of accidents Improper mounting of cases or the tank rucksack impairs the handling characteris- tic. – Mount and secure cases and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. –...
  • Page 95 PREPARING FOR USE 9 Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic. – Check that your luggage is fixed properly at regular intervals. Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 96: Riding Instructions

    10 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 97: Starting The Vehicle

    RIDING INSTRUCTIONS 10 – Check the fuel level. 10.2 Starting the vehicle 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. –...
  • Page 98 10 RIDING INSTRUCTIONS – Press the emergency OFF switch to the position ON – Switch on the ignition by turning the black ignition key to the position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time.

  • Page 99: Starting Off

    RIDING INSTRUCTIONS 10 Info Do not press the electric starter button until the combi- nation instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

  • Page 100: Shifting, Riding

    10 RIDING INSTRUCTIONS 10.4 Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – Adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
  • Page 101 RIDING INSTRUCTIONS 10 Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. – Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot rest and holds on to the rider or the grab handles. –...
  • Page 102 10 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.
  • Page 103 Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.).
  • Page 104 If the oil pressure warning lamp lights up during a trip, stop immediately and switch off the engine. Contact an authorized KTM workshop. – If the malfunction indicator lamp lights up during a trip, please contact an authorized KTM workshop as soon as possi- ble.

  • Page 105: Applying The Brakes

    RIDING INSTRUCTIONS 10 Info You can deduce a two-digit number from the flash rhythm – the so-called blink code. The blink code tells you which component is affected by a malfunction. – If the general warning lamp lights up during a trip, the matrix display shows a message for 10 seconds.
  • Page 106 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 107 RIDING INSTRUCTIONS 10 Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. The ABS effectiveness is only ensured if it is switched on. – Leave the ABS switched on in order to benefit from the protective effect. Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations.

  • Page 108: Stopping, Parking

    10 RIDING INSTRUCTIONS Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. – If possible finish braking before going into a bend. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
  • Page 109 RIDING INSTRUCTIONS 10 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. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking.

  • Page 110: Transporting

    10 RIDING INSTRUCTIONS – Lock the steering by turning the handlebar to the left, pressing the black ignition key down in the position OFF and turning it to the position LOCK . To make the steering lock engage more easily, move the handlebar a little to the left and right.

  • Page 111: Refueling

    RIDING INSTRUCTIONS 10 – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away. 401475-01 10.8 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 112 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.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.
  • Page 113 RIDING INSTRUCTIONS 10 – Switch off the engine. – Open the filler cap. ( p. 40) – Fill the fuel tank with fuel up to the lower edge of the filler neck. Total fuel tank 23 l Super unleaded capacity, approx. (6.1 US gal) (ROZ 95/RON 95/PON 91)

  • Page 114: Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
  • Page 115 SERVICE SCHEDULE 11 Every two years Every year every 30,000 km (18,600 mi) every 15,000 km (9,300 mi) after 1,000 km (620 mi) ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. ○ ● ● ● Check the front brake fluid level. ( p.
  • Page 116 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 117: Recommended Work

    SERVICE SCHEDULE 11 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. ○ ● ● Check/clean the oil nozzle for clutch lubrication. ●...

  • Page 118: Suspension Setting

    12 SUSPENSION SETTING 12.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to the riding style and the payload. Info The recommendations for the suspension setting are shown in table . The table is found on the left inside cover of the fuel tank.
  • Page 119 SUSPENSION SETTING 12 – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in left fork leg COMP (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 120: Adjusting The Rebound Damping Of The Fork

    12 SUSPENSION SETTING 12.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the right fork leg.

  • Page 121: Adjusting The Spring Pretension Of The Fork

    SUSPENSION SETTING 12 Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. 12.4 Adjusting the spring pretension of the fork – Turn adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –...

  • Page 122: Compression Damping Of The Shock Absorber

    12 SUSPENSION SETTING Info Turn clockwise to increase the spring pretension; turn counterclockwise to reduce the spring pretension. Adjusting the spring pretension has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damp- ing higher with a higher spring pretension.

  • Page 123: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 124: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.
  • Page 125 SUSPENSION SETTING 12 – Turn adjusting screw all the way clockwise with a socket wrench. Info Do not loosen fitting – Turn counterclockwise by the number of turns corresponding to the shock absorber type. Guideline S01779-10 Compression damping, high-speed Comfort 1.5 turns Standard 1.5 turns...

  • Page 126: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached 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 127: Adjusting The Spring Pretension Of The Shock Absorber

    SUSPENSION SETTING 12 12.9 Adjusting the spring pretension of the shock absorber – Turn handwheel counterclockwise as far as it will go. – Turn it clockwise by the number of turns corresponding to the shock absorber type and use. Guideline Spring preload Comfort 12 turns...

  • Page 128: Service Work On The Chassis

    13 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 129: Lifting The Motorcycle With The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 13 – 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 130: Taking The Motorcycle Off The Front Lifting Gear

    13 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. – Attach the front lifting gear with the adapter on the steering stem. Mounting pin (69329965040) Front wheel work stand, large (69329965000) – Align the front lifting gear with the fork legs. 402345-01 Info Always raise the motorcycle at the rear first.

  • Page 131: Raising The Motorcycle With The Work Stand (Inserted)

    SERVICE WORK ON THE CHASSIS 13 Main work – Secure the motorcycle against falling over. – Remove the front lifting gear. 402777-01 Finishing work – Install the bottom triple clamp cover. ( p. 147) 13.5 Raising the motorcycle with the work stand (inserted) Note Danger of damage The parked vehicle can roll away or fall over.
  • Page 132 13 SERVICE WORK ON THE CHASSIS – Fold up the rider footrests and secure them. – Allow the work stand with plastic bushing to engage in the opening of the swingarm pivot. Work stand (62529055100) Info Set the work stand to an appropriate height and width. –...

  • Page 133: Removing The Motorcycle From The Work Stand (Inserted)

    SERVICE WORK ON THE CHASSIS 13 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.
  • Page 134 13 SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove special tool Work stand (62529055100) Info To avoid damaging components, lower the motorcycle slowly from the work stand. The assistance of a second person can be useful. –...

  • Page 135: Removing The Seat

    SERVICE WORK ON THE CHASSIS 13 13.7 Removing the seat – Insert the ignition key in the seat lock and turn it clock- wise by 45 °. – Raise the rear of the seat, pull the seat back, and lift it off. –...

  • Page 136: Checking For Chain Dirt

    13 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. 134) 400678-01 13.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...
  • Page 137 SERVICE WORK ON THE CHASSIS 13 Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 138: Checking The Chain Tension

    13 SERVICE WORK ON THE CHASSIS 13.11 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 139: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 13 Chain tension 40 … 45 mm (1.57 … 1.77 in) » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 137) Finishing work – Remove the rear of the motorcycle from the lifting gear. p.
  • Page 140 13 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 40 … 45 mm (1.57 … 1.77 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in...

  • Page 141: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 13 Guideline Nut, rear wheel M25x1.5 90 Nm (66.4 lbf ft) Thread greased spindle Info Chain adjusters can be turned by 180°. Finishing work – Remove the rear of the motorcycle from the lifting gear. p.
  • Page 142 13 SERVICE WORK ON THE CHASSIS – Shift the transmission to idle – Pull the lower chain section with specified weight Guideline Weight, chain wear measure- 15 kg (33 lb.) ment – Measure the distance of 18 chain rollers on the upper part of the chain.
  • Page 143 SERVICE WORK ON THE CHASSIS 13 – Check the chain sliding guard for wear at the recess. Info When the chain sliding guard is new, the rivets 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 144: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    13 SERVICE WORK ON THE CHASSIS Guideline Screw, chain 5 Nm (3.7 lbf ft) guide Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 126) 13.14 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs.
  • Page 145 SERVICE WORK ON THE CHASSIS 13 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container 4 mm (0.16 in) »...

  • Page 146: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages 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 147 SERVICE WORK ON THE CHASSIS 13 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. Play should not be detectable on the steering head bearing.

  • Page 148: Removing The Bottom Triple Clamp Cover

    13 SERVICE WORK ON THE CHASSIS 13.16 Removing the bottom triple clamp cover – Remove screws – Lower triple clamp cover slightly. M00557-10 – Disconnect plugs of the horn. – Detach temperature sensor – Remove the triple clamp cover. M00558-10...

  • Page 149: Installing The Bottom Triple Clamp Cover

    SERVICE WORK ON THE CHASSIS 13 13.17 Installing the bottom triple clamp cover – Plug in connectors of the horn. – Attach temperature sensor M00558-11 – Position the triple clamp cover – Mount and tighten screws Guideline Remaining chassis 10 Nm (7.4 lbf ft) screws M00557-11...

  • Page 150: Removing The Front Side Cover

    13 SERVICE WORK ON THE CHASSIS 13.18 Removing the front side cover – Remove screw S01786-10 – Remove screws – Remove side cover – Repeat these steps on the opposite side. S01787-10...

  • Page 151: Installing The Front Side Cover

    SERVICE WORK ON THE CHASSIS 13 13.19 Installing the front side cover – Position the side cover in the area under the tank cover. S01788-10 – Attach catch of the side cover to bracket and position on the fuel tank. The holding lug engages in the hole S01789-10...

  • Page 152: Removing The Mask Spoiler

    13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) S01786-11 – Mount and tighten screws Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) – Repeat these steps on the opposite side. S01790-10 13.20 Removing the mask spoiler...
  • Page 153 SERVICE WORK ON THE CHASSIS 13 Main work – Remove screw S01791-10 – Remove screw S01792-10...
  • Page 154 13 SERVICE WORK ON THE CHASSIS – Loosen holding lug from the inside cover. S01793-10 – Remove the mask spoiler laterally from the supports. S01794-10...
  • Page 155 SERVICE WORK ON THE CHASSIS 13 – Pull the mask spoiler upward from bracket S01795-10 – Disconnect plug-in connector – Remove the mask spoiler with the turn signal. – Repeat the operation on the opposite side. S01796-10...

  • Page 156: Installing The Mask Spoiler

    13 SERVICE WORK ON THE CHASSIS 13.21 Installing the mask spoiler Main work – Connect plug-in connector S01796-11 – Position the mask spoiler in bracket Info Ensure that the turn signal cable is placed correctly. S01795-11...
  • Page 157 SERVICE WORK ON THE CHASSIS 13 – Press the mask spoiler laterally into the supports. S01794-11 – Position holding lug in the drill hole. S01793-10...
  • Page 158 13 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) S01792-11 – Mount and tighten screw Guideline Screw, mask spoiler M5x17 3.5 Nm (2.58 lbf ft) – Repeat the operation on the opposite side. S01791-11 Finishing work –...

  • Page 159: Removing Front Fender

    SERVICE WORK ON THE CHASSIS 13 13.22 Removing front fender – Open holder and detach the brake lines and cable. – Remove screws – Take the fender off to the front. Info Pay attention to the brake lines and the cable. S01797-10 13.23 Installing front fender...

  • Page 160: Cleaning The Dust Boots Of The Fork Legs

    13 SERVICE WORK ON THE CHASSIS – Insert the brake lines and cable in brackets and close the holder. 13.24 Cleaning the dust boots of the fork legs Preparatory work – Remove front fender. ( p. 157) – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 161 SERVICE WORK ON THE CHASSIS 13 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 nec- essary.

  • Page 162: Removing The Tank Cover

    13 SERVICE WORK ON THE CHASSIS 13.25 Removing the tank cover Preparatory work – Remove the seat. ( p. 133) – Remove the front side cover. ( p. 148) Main work – Remove screw – Remove screw S01798-10 – Remove screw –...
  • Page 163 SERVICE WORK ON THE CHASSIS 13 – Remove screw S01800-10 – Raise the tank cover at the rear and take it off in a forward direction. S01801-01...

  • Page 164: Installing The Tank Cover

    13 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. S01802-10 – Mount and tighten screw Guideline Screw, cover part 3.5 Nm...
  • Page 165 SERVICE WORK ON THE CHASSIS 13 – 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) S01799-11 – Mount and tighten screw Guideline Screw, cover part 6 Nm (4.4 lbf ft)

  • Page 166: Removing The Wind Shield

    13 SERVICE WORK ON THE CHASSIS 13.27 Removing the wind shield – Remove screws and wind shield S01803-10 13.28 Installing the wind shield – Position wind shield – Mount and tighten screws Guideline Screw, wind shield 3.5 Nm (2.58 lbf ft) S01803-11...

  • Page 167: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS 13 13.29 Removing the engine guard – Remove screws with bushings and engine guard S01804-10 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) S01804-11...

  • Page 168: Removing The Crash Bar

    13 SERVICE WORK ON THE CHASSIS 13.31 Removing the crash bar – Remove fittings D03196-10 – Remove screws and take off the clamp halves. D03197-10...
  • Page 169 SERVICE WORK ON THE CHASSIS 13 – Remove screw – Remove screw – Take off the left crash bar. D03198-10 – Remove screws and take off the clamp halves. D03199-10...

  • Page 170: Installing The Crash Bar

    13 SERVICE WORK ON THE CHASSIS – Remove screw – Remove screw – Take off the right crash bar. D03200-10 13.32 Installing the crash bar – Position the right crash bar with the frame protector. The tank holding rubber should be correctly positioned on the fuel tank.
  • Page 171 SERVICE WORK ON THE CHASSIS 13 Guideline Remaining chassis 10 Nm (7.4 lbf ft) screws – Mount screws with clamp halves, but do not tighten yet. Guideline Remaining chassis 10 Nm (7.4 lbf ft) screws D03199-11 – Position the left crash bar with the frame protector. The tank holding rubber should be correctly positioned on the fuel tank.
  • Page 172 13 SERVICE WORK ON THE CHASSIS – Mount screw but do not tighten yet. Guideline Remaining chassis 10 Nm (7.4 lbf ft) screws – Mount screws with clamp halves, but do not tighten yet. Guideline Remaining chassis 10 Nm (7.4 lbf ft) screws D03197-11 –...

  • Page 173: Service Work On The Chassis 13

    SERVICE WORK ON THE CHASSIS 13 Guideline Remaining chassis 10 Nm (7.4 lbf ft) screws Remaining chassis 45 Nm (33.2 lbf ft) screws...

  • Page 174: Brake System

    – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. 0 0 1 – Maintain the specified tire air pressure.
  • Page 175 BRAKE SYSTEM 14 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 invalidated. – Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off com- pletely.
  • Page 176 14 BRAKE SYSTEM There is no ABS intervention on the rear wheel in ABS control Offroad. The ABS indicator lamp flashes slowly to remind you that the Offroad ABS mode is enabled. Info In the Offroad ABS mode, the rear wheel may lock and there is a risk of falling.

  • Page 177: Checking The Brake Discs

    Warning 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 front and rear brake disc thickness at multiple...

  • Page 178: Checking The Front Brake Fluid Level

    KTM workshop will be glad to help.) Warning 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.)

  • Page 179: Adding Front Brake Fluid

    If the brake fluid level drops below the specified marking or the specified value, 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 180 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 181 BRAKE SYSTEM 14 Info Never use 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 attacks paint. Only use clean brake fluid from a sealed container.

  • Page 182: Checking The Front Brake Linings

    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.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 183: 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 184: Adding Rear Brake Fluid

    – 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.) – Check the brake fluid level in the brake fluid reservoir »...
  • Page 185 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 186 14 BRAKE SYSTEM Info Never use 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 attacks paint. Only use clean brake fluid from a sealed container.

  • Page 187: Checking The Rear Brake Linings

    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.

  • Page 188: Wheels, Tires

    15 WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 126) – Remove the bottom triple clamp cover. ( p. 146) – Lift the motorcycle with the front lifting gear. ( p.
  • Page 189 WHEELS, TIRES 15 – Remove screws from both brake calipers. – Press back the brake linings with a slight lateral tilting of the brake calipers on the brake disc. – Pull the brake calipers carefully back from the brake discs and hang them to one side loosely.

  • Page 190: Installing The Front Wheel

    15 WHEELS, TIRES Info Do not pull the hand brake lever when the front wheel is removed. – Remove spacers H02027-10 15.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...
  • Page 191 WHEELS, TIRES 15 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.
  • Page 192 15 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 nec- essary. – S00962-10 Clean and lightly grease screw and wheel spindle...

  • Page 193: Nm (7.4 Lbf Ft)

    WHEELS, TIRES 15 – Position the brake calipers. The brake linings are correctly positioned. – Mount screws on both brake calipers but do not tighten yet. – Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.

  • Page 194: Removing The Rear Wheel

    15 WHEELS, TIRES – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) K00540-11 Finishing work – Install the bottom triple clamp cover. ( p.
  • Page 195 WHEELS, TIRES 15 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. S01832-10 – Remove screw and pull wheel speed sensor out of the hole. S01830-10...
  • Page 196 15 WHEELS, TIRES – Remove nut . Remove chain adjuster S01831-10 – Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Take the chain off of the rear sprocket and place it on chain sprocket guard Warning Danger of accidents Damaged brake discs reduce the...

  • Page 197: Installing The Rear Wheel

    WHEELS, TIRES 15 Info Do not operate the foot brake when the rear wheel is removed. – Remove spacer 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. –...
  • Page 198 15 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal ring and contact surface the spacer. Long-life grease ( p.
  • Page 199 WHEELS, TIRES 15 – Push the wheel spindle in all the way and mount chain adjuster and nut Info Mount chain adjusters in the same posi- tion. – Make sure that the chain adjusters are fitted correctly on the adjusting screws. S01835-10 Guideline In order for the rear wheel to be correctly aligned, the mark-...

  • Page 200: Checking The Rear Hub Rubber Dampers

    15 WHEELS, TIRES – Position wheel speed sensor in the drill hole. – Mount and tighten screw Guideline Screw, wheel speed 10 Nm (7.4 lbf ft) sensor, rear – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.
  • Page 201 WHEELS, TIRES 15 Main work – Check 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. S01836-10 –...

  • Page 202: Checking The Tire Condition

    Warning 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 charac- teristic.
  • Page 203 WHEELS, TIRES 15 Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened. – Run in new tires with moderate riding at alternating angles. Running-in phase 200 km (124 mi) Info Tire type, tire condition, and tire air pressure influence the braking and handling characteristics of the vehicle.

  • Page 204: Checking The Tire Air Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-10 years at the latest, regardless of the actual state of wear.

  • Page 205: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)
  • Page 206 15 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 207: Tubeless Tire System

    The rigid rim design results in a spoke wheel that is almost entirely maintenance-free. KTM recommends that the tubeless sealing profile be changed after 5 years at the latest, regardless of the actual state of wear. 310767-10...

  • Page 208: Electrical System

    16 ELECTRICAL SYSTEM 16.1 Daytime running light 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 visi- bility is significantly impaired due to fog, snow or rain.

  • Page 209: Removing The Battery

    ELECTRICAL SYSTEM 16 When the daytime running light is switched off, it serves as a posi- tion light. 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. –...
  • Page 210 16 ELECTRICAL SYSTEM Main work – Pull locking mechanism in the direction of the arrow. – Fold open cover S01811-10 – Disconnect negative cable from the battery. – Disconnect positive cable from the battery. – Take the battery and battery case out of the battery com- partment.

  • Page 211: Installing The Battery

    ELECTRICAL SYSTEM 16 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 212 16 ELECTRICAL SYSTEM Main work – Position the battery in battery case Guideline The even side of the battery case must be opposite the poles. – Position the battery and battery case in the battery compart- ment. – Position the positive cable and mount and tighten the S01812-11 screw.
  • Page 213 ELECTRICAL SYSTEM 16 – Close the cover and push down slightly. The cover engages with an audible click. S01813-10 Finishing work – Mount the seat. ( p. 133) – Set the time and date.

  • Page 214: Recharging The Battery

    16 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 215 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 instruc- tions on the battery housing.
  • Page 216 16 ELECTRICAL SYSTEM Main work – Pull locking mechanism in the direction of the arrow. – Fold open cover S01811-10 – Disconnect both negative cables of the battery to avoid damage to the motorcycle's electronics. S01814-10...
  • Page 217 ELECTRICAL SYSTEM 16 – Connect the battery charger to the battery. Switch on the bat- tery 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 218 16 ELECTRICAL SYSTEM – Connect both negative cables to the battery. Guideline Screw, battery termi- 4.5 Nm (3.32 lbf ft) S01814-10 – Close cover and push down slightly. The cover engages with an audible click. S01813-10 Finishing work – Mount the seat. ( p.

  • Page 219: Changing The Main Fuse

    ELECTRICAL SYSTEM 16 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 the ignition by turning the black ignition key to the position OFF –...
  • Page 220 16 ELECTRICAL SYSTEM – Take off protection caps S01816-10 – 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 221 ELECTRICAL SYSTEM 16 Insert a new spare fuse into the starter relay to have it available when needed. – Position rear fairing – Mount and tighten screws Guideline Screw, cover part 3.5 Nm (2.58 lbf ft) S01815-10 Finishing work – Mount the seat.

  • Page 222: Changing The Fuses In The Fuse Box

    16 ELECTRICAL SYSTEM 16.6 Changing the fuses in the fuse box Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work –...
  • Page 223 ELECTRICAL SYSTEM 16 Main work – Open fuse box cover S01818-10 – Check the fuses. Info You can recognize a faulty fuse by a burned-out fuse wire – Remove the faulty fuse. S01819-10...
  • Page 224 16 ELECTRICAL SYSTEM Guideline Fuse res - 10 A - spare fuses Fuse 1 - 10 A - power supply for control units and compo- nents Fuse 2 - 10 A - permanent positive for auxiliary equipment (ACC1) Fuse 3 - 15 A - ABS hydraulic unit Fuse 4 - 25 A - ABS return pump Fuse 5 - not assigned –...

  • Page 225: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 16 16.7 Removing the headlight mask with the headlight Preparatory work – Switch off the ignition by turning the black ignition key to the position OFF – Remove the seat. ( p. 133) – Remove the front side cover. ( p.

  • Page 226: Installing The Headlight Mask With The Headlight

    16 ELECTRICAL SYSTEM – Disconnect plug-in connector – Place the headlight mask onto a soft cloth so that the head- light is not damaged. S01821-10 16.8 Installing the headlight mask with the headlight Main work – Connect plug-in connector of the headlight. –...
  • Page 227 ELECTRICAL SYSTEM 16 – Mount and tighten screws Guideline Screw, headlight 5 Nm (3.7 lbf ft) S01820-11 Finishing work – Install the wind shield. ( p. 164) – Install the mask spoiler. p. 154) – Install the tank cover. ( p.

  • Page 228: Changing The Low Beam Bulb

    16 ELECTRICAL SYSTEM 16.9 Changing the low beam bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...
  • Page 229 ELECTRICAL SYSTEM 16 Main work – Remove cable tie(s) – Push headlight bulb lightly into the bulb socket, turn it all the way counterclockwise, and pull it out. – Unplug connector S01822-10 – Plug in connector into the new headlight bulb. Low beam (H11/socket PGJ19-2) ( p.

  • Page 230: Changing The High Beam Bulb

    16 ELECTRICAL SYSTEM – Mount the seat. ( p. 133) – Check the headlight setting. ( p. 231) 16.10 Changing the high beam bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...
  • Page 231 ELECTRICAL SYSTEM 16 Main work – Push headlight bulb lightly into the bulb socket, turn it all the way counterclockwise, and pull it out. – Unplug connector S01824-10 – Plug connector into the new headlight bulb. High beam (H11/socket PGJ19-2) ( p.

  • Page 232: Changing The Turn Signal Bulb

    16 ELECTRICAL SYSTEM – Mount the seat. ( p. 133) – Check the headlight setting. ( p. 231) 16.11 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...

  • Page 233: Checking The Headlight Setting

    ELECTRICAL SYSTEM 16 – 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 – Park the vehicle on a horizontal surface in front of a light- colored wall and make a mark at the height of the center of the low beam headlight.

  • Page 234: Adjusting The Headlight Range

    16 ELECTRICAL SYSTEM The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: –...

  • Page 235: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM 16 – Set the headlight to marking Guideline The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applica- ble.
  • Page 236 16 ELECTRICAL SYSTEM Loss of a black ignition key (additional black ignition keys are available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Press the emergency OFF switch to the position ON 401114-10 –...
  • Page 237 ELECTRICAL SYSTEM 16 – Switch on the ignition by turning the orange programming key to the ON position The immobilizerindicator lamp flashes according to the number of functional black ignition keys including the orange programming key. In this case, it flashes twice.
  • Page 238 16 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 239 ELECTRICAL SYSTEM 16 – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. – Insert the black ignition key in the ignition lock. – Switch on the ignition by turning the black ignition key to the position ON Immobilizer indicator lamp lights up.
  • Page 240 16 ELECTRICAL SYSTEM Info Activation of the ignition key is finished. To activate four black ignition keys: – Press the emergency OFF switch to the position ON – 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.

  • Page 241: Diagnostics Connector

    ELECTRICAL SYSTEM 16 Info As soon as the fourth black ignition key has been activated, programming is finished. 16.15 Diagnostics connector Diagnostics connector is located under the seat. F00730-10...

  • Page 242: Front Acc1 And Acc2

    16 ELECTRICAL SYSTEM 16.16 Front ACC1 and ACC2 Installation location – The front power supplies ACC1 and ACC2 are located behind the headlight. Info The power supplies are protected by a fuse, however this fuse also protects other power consumers. The maximum continuous load is therefore significantly lower than the value of the fuse.

  • Page 243: Cooling System 17

    COOLING SYSTEM 17 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 operating temperature.
  • Page 244 17 COOLING SYSTEM – Park the motorcycle on a horizontal surface. – Check the coolant level in the compensating tank The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: – Check the cooling system for leaks.

  • Page 245: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM 17 17.2 Correcting 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 operating temperature.
  • Page 246 17 COOLING SYSTEM Info Only disassemble the right-hand side. Main work – Remove cover of the compensating tank. S01828-10 – Add coolant until the coolant reaches the specified level. Guideline The coolant level must be between MIN and MAX. Coolant ( p.

  • Page 247: Tuning The Engine 18

    TUNING THE ENGINE 18 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 248: Traction Control (Tc)

    18 TUNING THE ENGINE 18.2 Traction control (TC) The traction control (TC) lowers the engine torque in case of loss of traction in the rear wheel. Depending on the motorcycle traction control setting, a slight slip on the rear wheel may be desirable. Example: offroad.

  • Page 249: Service Work On The Engine 19

    SERVICE WORK ON THE ENGINE 19 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 250: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    19 SERVICE WORK ON THE ENGINE » When the engine oil level is in area of the engine oil level viewer: – Add engine oil. ( p. 255) 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.
  • Page 251 SERVICE WORK ON THE ENGINE 19 Main work – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove oil drain plugs with the magnets, O-rings, and oil screens. S00333-10 –...
  • Page 252 19 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. S01838-10 – Insert new oil filter Info Only insert the oil filter by hand.
  • Page 253 SERVICE WORK ON THE ENGINE 19 – Mount and tighten screws Guideline Remaining screws for 6 Nm (4.4 lbf ft) engine S00334-11 – Thoroughly clean magnets and oil screens of the oil drain plugs. 100773-12...
  • Page 254 19 SERVICE WORK ON THE ENGINE – Mount and tighten oil drain plugs with the magnets, O- rings, and oil screens. Guideline Oil drain plug M20x1.5 20 Nm (14.8 lbf ft) S00333-10 – Have the entire filling quantity available. Engine oil 3.60 l Engine oil Outside temperature:...
  • Page 255 SERVICE WORK ON THE ENGINE 19 Engine oil (1st par- 3.0 l (3.2 qt.) Engine oil (SAE tial quantity) approx. 5W/40) ( p. 289) Outside temperature: < 0 °C (< 32 °F) – Mount screw plug Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.
  • Page 256 19 SERVICE WORK ON THE ENGINE – Remove the screw plug and add the second partial quantity up to the upper marking on the engine oil level viewer. Engine oil (2nd par- 0.60 l Engine oil tial quantity) approx. (0.63 qt.) (SAE 10W/50) Outside temperature: p.

  • Page 257: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 19 – Install the engine guard. ( p. 165) 19.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. The engine may be damaged if the engine oil level is too high. Condition The engine is at operating temperature.
  • Page 258 289) S00329-10 Info In order to achieve optimal engine performance, it is not advisable to mix different engine oils. KTM recommends changing the engine oil. – Mount the screw plug. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.
  • Page 259 SERVICE WORK ON THE ENGINE 19 Finishing work – Check the engine oil level. ( p. 247)

  • Page 260: Cleaning, Care

    20 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 261 CLEANING, CARE 20 – 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 262 20 CLEANING, CARE – After cleaning, ride the vehicle a short distance until the engine warms up. Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate.

  • Page 263: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 20 – Treat the plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 292) – Oil the ignition/steering lock, tank lock, and seat lock. Universal oil spray ( p.
  • Page 264 20 CLEANING, CARE – Clean the motorcycle. ( p. 258) – 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 265: Storage 21

    STORAGE 21 21.1 Storage Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them per- formed. 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 266: Preparing For Use After Storage

    21 STORAGE – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. – Cover the vehicle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 267: Troubleshooting 22

    212) – Check the open-circuit current. – Safety start system is faulty Read out the fault memory using the KTM diagnostics tool. – ICU is not enabled Activate the ICU. – CAN bus communication error Read out the fault memory using the KTM diagnostics tool.
  • Page 268 Shift the transmission to idle lever is drawn – Safety start system is faulty Read out the fault memory using the KTM diagnostics tool. – Engine turns although a gear is Safety start system is faulty Read out the fault memory using the engaged KTM diagnostics tool.
  • Page 269 TROUBLESHOOTING 22 Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 247) – Engine oil too thin (low viscos- Change the engine oil and oil filter and ity) clean the oil screens. p.

  • Page 270: Technical Data

    23 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...
  • Page 271 TECHNICAL DATA 23 Engine lubrication Pressure circulation lubrication with three rotary pumps Primary transmission 40:76 Clutch Antihopping clutch in oil bath/hydraulically operated Transmission 6-speed claw gears Transmission ratio 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear...

  • Page 272: Engine Tightening Torques

    23 TECHNICAL DATA Cold start device Electric starter 23.2 Engine tightening torques Screw, damping plate EJOT ALtracs ® M6x14 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, retaining bracket, valve EJOT ALtracs ® M6x10 10 Nm (7.4 lbf ft) cover, rear Hose clip, intake flange 1.5 Nm (1.11 lbf ft)
  • Page 273 TECHNICAL DATA 23 M6 – 10.9 Freewheel ring bolt 15 Nm (11.1 lbf ft) Loctite ® 648™ Nut, cylinder head 9 Nm (6.6 lbf ft) Plug, vacuum connection 5 Nm (3.7 lbf ft) Loctite ® 243™ Remaining engine screws 10 Nm (7.4 lbf ft) M6 –...
  • Page 274 23 TECHNICAL DATA Screw, stator 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite ®...
  • Page 275 TECHNICAL DATA 23 Screw, timing chain guide rail 15 Nm (11.1 lbf ft) Loctite ® 243™ Screw, timing chain tensioning rail 15 Nm (11.1 lbf ft) Loctite ® 243™ Stud, exhaust flange 10 Nm (7.4 lbf ft) Screw, engine bearer 45 Nm (33.2 lbf ft) Oil pressure sensor M10x1...
  • Page 276 23 TECHNICAL DATA Cylinder head screw M11x1.5 Tightening sequence: Using a crisscross pattern Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° Step 4 90° Lubricated with engine oil Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) Screw, rotor...

  • Page 277: Capacities

    TECHNICAL DATA 23 23.3 Capacities 23.3.1 Engine oil Engine oil 3.60 l (3.8 qt.) Engine oil (SAE 10W/50) Outside temperature: ≥ 0 °C p. 288) (≥ 32 °F) Engine oil Engine oil (SAE 5W/40) ( p. 289) Outside temperature: < 0 °C (<...

  • Page 278: Chassis

    23 TECHNICAL DATA 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tub- ing, powder-coated Fork WP Performance Systems 4860 ROTA SPLIT WP Performance Systems 4618 DCC PA Shock absorber Suspension travel front 220 mm (8.66 in) rear 220 mm (8.66 in) Brake system front Double disc brake with radially mounted, four-pot...

  • Page 279: Electrical System

    TECHNICAL DATA 23 rear: with cold tires 2.9 bar (42 psi) Secondary drive ratio 17:42 Chain 5/8 x 5/16” (525) X‑ring Steering head angle 64° Wheelbase 1,580 ± 15 mm (62.2 ± 0.59 in) Seat height, unloaded 890 mm (35.04 in) Ground clearance, unloaded 250 mm (9.84 in) Weight without fuel, approx.

  • Page 280: Tires

    90/90 - 21 M/C 54T M+S TL 150/70 B 18 M/C 70Q M+S TL Continental TKC 80 Twinduro Continental TKC 80 Twinduro The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...

  • Page 281: Fork

    TECHNICAL DATA 23 23.7 Fork Fork article number 14.18.8Q.25 WP Performance Systems 4860 ROTA SPLIT Fork Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks...

  • Page 282: Shock Absorber

    23 TECHNICAL DATA Medium (standard) 6.5 N/mm (37.1 lb/in) Hard 7.0 N/mm (40 lb/in) Fork length 920 mm (36.22 in) Air chamber length mm (3.35 + 35 + 1.38 − 0 − 0 Fork oil per fork leg 715 ml (24.17 fl. oz.) Fork oil (SAE 4) (48601166S1) p.
  • Page 283 TECHNICAL DATA 23 Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Comfort 12 turns Standard 12 turns Sport 12 turns Full payload 18 turns Spring rate Soft 170 N/mm (971 lb/in) Medium (standard) 180 N/mm (1,028 lb/in) Hard 190 N/mm (1,085 lb/in)

  • Page 284: Chassis Tightening Torques

    23 TECHNICAL DATA 23.9 Chassis tightening torques Nut, valve ISO 10V2 12 Nm (8.9 lbf ft) Loctite ® 2701™ Screw, combination switch, left 2 Nm (1.5 lbf ft) Screw, side stand switch 2 Nm (1.5 lbf ft) Rear fairing screw M5x12 3.5 Nm (2.58 lbf ft) Rear fairing screw...
  • Page 285 TECHNICAL DATA 23 Screw, heat guard on main silencer M5 4 Nm (3 lbf ft) Screw, wind shield 3.5 Nm (2.58 lbf ft) Spoke nipple 5 Nm (3.7 lbf ft) Ground fitting on frame 6 Nm (4.4 lbf ft) Nut, ABS module fastening 8 Nm (5.9 lbf ft) Remaining chassis nuts 10 Nm (7.4 lbf ft)
  • Page 286 23 TECHNICAL DATA Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, front wheel speed sensor 10 Nm (7.4 lbf ft) Screw, fuel pump 6 Nm (4.4 lbf ft) Screw, fuel tank 10 Nm (7.4 lbf ft) Screw, fuel tap 6 Nm (4.4 lbf ft) Screw, headlight...
  • Page 287 TECHNICAL DATA 23 Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front footrest bracket 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handle bar end hand guard 25 Nm (18.4 lbf ft) Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, ignition lock (tamper-proof 25 Nm (18.4 lbf ft) Loctite...
  • Page 288 23 TECHNICAL DATA Screw, side stand 35 Nm (25.8 lbf ft) Loctite ® 243™ Screw, side stand bracket 45 Nm (33.2 lbf ft) Loctite ® 243™ Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) Nut, rear sprocket screw M10x1.25 50 Nm (36.9 lbf ft) Loctite...

  • Page 289: Substances 24

    SUBSTANCES 24 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 – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 290 24 SUBSTANCES The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted. The use of premixed coolant is recommended. Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.
  • Page 291 SUBSTANCES 24 Engine oil (SAE 5W/40) Standard/classification – JASO T903 MA ( p. 293) – SAE ( p. 293) (SAE 5W/40) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
  • Page 292 24 SUBSTANCES Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline –...

  • Page 293: Auxiliary Substances 25

    AUXILIARY SUBSTANCES 25 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 ® –...
  • Page 294 25 AUXILIARY SUBSTANCES Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® –...

  • Page 295: Standards 26

    STANDARDS 26 JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 296: Index Of Special Terms

    27 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 dur- ing the day but is not focused, and in contrast to low...

  • Page 297: List Of Abbreviations 28

    LIST OF ABBREVIATIONS 28 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 298: List Of Symbols

    29 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 immobi- lizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low. Stop immedi- ately, taking care not to endanger yourself or other road users in the process, and switch off the engine.

  • Page 299: Green And Blue Symbols

    LIST OF SYMBOLS 29 29.3 Green and blue symbols Green and blue symbols reflect information. The high beam indicator lamp lights up blue – The high beam is switched on. The left turn signal lamp flashes green with a steady rhythmic flash – The left turn signal is switched on.

  • Page 300: Index

    INDEX Brake fluid level INDEX front brake, checking ....176 ABS ....... 172 rear brake, checking .
  • Page 301 INDEX Clutch service display ..... . 60 fluid level, checking/correcting ..142 "Set Favorites"...
  • Page 302 INDEX Emergency OFF switch ....36 Footrests adjusting ......82 Engine Fork .
  • Page 303 INDEX Immobilizer ......38 Intended use ......12 Hand brake lever .
  • Page 304 INDEX raising with the rear lifting gear ..126 raising with work stand (inserted) ..129 Rear hub rubber dampers removing from the work stand (inserted) .
  • Page 305 INDEX Shift lever ......48 Storage ......263 basic position, adjusting .
  • Page 306 INDEX Throttle grip ......31 View of vehicle front left ......22 Tire air pressure rear right .
  • Page 307 *3213756en* 3213756en 10/2017 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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