KTM 200 Duke US 2020 Owner's Manual
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KTM 200 Duke US 2020 Owner's Manual

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OWNER'S MANUAL
2020
200 Duke
Art. no. 3214156en

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Summary of Contents for KTM 200 Duke US 2020

  • Page 1 OWNER'S MANUAL 2020 200 Duke Art. no. 3214156en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
  • 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) KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Fuel, auxiliary substances ....23 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 8 Spare parts, accessories ....23 Symbols used ........8 Service ........... 24 Formats used........9 Figures ........... 24 SAFETY ADVICE.......... 10 Customer service......24 Use definition –...
  • Page 6 TABLE OF CONTENTS Start button........36 7.12 TRIP 1 display......... 62 6.10 Ignition and steering lock....36 7.13 TRIP 2 display......... 63 6.11 Locking the steering ......37 7.14 riding time/average speed menu ..64 6.12 Unlocking the steering...... 38 7.15 average speed/average fuel consumption 1 menu .......
  • Page 7 TABLE OF CONTENTS Starting off........83 12.5 Cleaning the dust boots of the fork legs ..........107 Shifting, riding........ 84 Applying the brakes......88 12.6 Removing the passenger seat ..109 12.7 Mounting the passenger seat... 110 Stopping, parking......90 12.8 Removing the front rider's seat ..
  • Page 8 TABLE OF CONTENTS 13.6 Checking the rear brake fluid 15.6 Changing the headlight bulb ... 165 level ..........131 15.7 Checking the headlight setting ..168 13.7 Adding rear brake fluid ....132 15.8 Adjusting the headlight range..169 13.8 Checking the rear brake linings ..
  • Page 9 TABLE OF CONTENTS 18.2 Changing the engine oil and oil 22.8 Shock absorber ......218 filter, cleaning the oil screen ..192 22.9 Chassis tightening torques ....218 18.3 Adding engine oil ......195 23 SUBSTANCES .......... 225 19 CLEANING, CARE ........198 24 AUXILIARY SUBSTANCES ......

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

  • Page 11: 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 12: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of road use. This vehicle is not suitable for use on race tracks or offroad. Info This vehicle is only authorized for operation on public roads in its homologated version. Misuse The vehicle must only be used as intended.

  • Page 13: Degrees Of Risk And Symbols

    SAFETY ADVICE 2 Info Various information and warning labels are attached in prominent locations on the product 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 Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the...

  • Page 14: Overview Of Labels

    2 SAFETY ADVICE Overview of labels S04248-10...
  • Page 15 SAFETY ADVICE 2 Type label for Canada Information on emissions control Information on preparations for use Type label for USA Information on noise emissions S04195-01 Type label for Canada...
  • Page 16 2 SAFETY ADVICE Information on emissions control S04196-01 Information on preparations for use F00491-01...
  • Page 17 SAFETY ADVICE 2 S04198-01 Type label for USA S04197-01 Information on noise emissions...

  • Page 18: Consumer Rights

    Manufacturer warranty for the exhaust monitoring system KTM North America, Inc. guarantees that, at the time of sale, the exhaust monitoring system complies with all the standards of the US Environmental Protection Agency (EPA) and the California Air Resources Board (CARB).

  • Page 19: Noise Emission Warranty

    As the owner of the motorcycle, you are responsible for the required maintenance specified in the Owner's Man- ual. Please note that KTM is entitled to reject warranty claims if your motorcycle or a part fails due to misuse, neg- ligence, an accident, participation in racing or similar events, improper maintenance or unauthorized modifica- tions.

  • Page 20: Reporting Safety Defects

    However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington,...

  • Page 21: Safe Operation

    SAFETY ADVICE 2 1 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

  • Page 22: Protective Clothing

    Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – 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.

  • Page 23: Work Rules

    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 24: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 25: Important Notes 3

    Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 26: Service

    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. International KTM Website: http://www.ktm.com...
  • Page 27 IMPORTANT NOTES 3...

  • Page 28: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S04246-10...
  • Page 29 VIEW OF VEHICLE 4 Combination instrument Clutch lever ( p. 32) Front rider’s seat Passenger seat Grab handles ( p. 42) Seat lock ( p. 41) Side stand ( p. 44) Shift lever ( p. 43)

  • Page 30: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) S04245-10...
  • Page 31 VIEW OF VEHICLE 4 Tool set ( p. 41) Light switch ( p. 34) Turn signal switch ( p. 35) Horn button ( p. 33) Ignition and steering lock ( p. 36) Emergency OFF switch ( p. 35) Start button ( p.

  • Page 32: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 402408-10 Type label The type label is on the right of the frame behind the steering head. 402174-10...

  • Page 33: Engine Number

    SERIAL NUMBERS 5 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 402486-10 Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 34: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. S00656-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever. S00663-10...

  • Page 35: Throttle Grip

    CONTROLS 6 Throttle grip The throttle grip is fitted on the right side of the handlebar. S00664-10 Horn button Horn button is fitted on the left side of the handlebar. Possible states • The horn button is in the basic position is pressed –...

  • Page 36: Light Switch

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

  • Page 37: Turn Signal Switch

    CONTROLS 6 Turn signal switch Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – Turn signal switch pushed toward the switch housing. Left turn signal, on – Turn signal switch pressed to the left.

  • Page 38: Start Button

    6 CONTROLS Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. S00662-10 6.10 Ignition and steering lock...

  • Page 39: Locking The Steering

    CONTROLS 6 Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed. 6.11 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.

  • Page 40: Unlocking The Steering

    6 CONTROLS 6.12 Unlocking the steering – Insert the ignition key into the ignition and steering lock, press in, and turn to the right. Remove the ignition key. The handlebar can now be moved again. 400731-01 6.13 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable.
  • Page 41 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 42: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Remove the ignition key. 6.14 Closing the fuel tank filler cap Warning Fire hazard Fuel is highly flammable, toxic and a health hazard. – Check that the fuel tank filler cap is locked cor- rectly after closing. – Change your clothing if fuel spills on them.

  • Page 43: Seat Lock

    CONTROLS 6 6.15 Seat lock The seat lock is located to the left of the seat. The seat lock can be unlocked using the ignition key. H01991-10 6.16 Tool set The tool set is located under the passenger seat. B00758-10...

  • Page 44: Grab Handles

    6 CONTROLS 6.17 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. K00726-10 6.18 Passenger foot pegs The passenger foot pegs can be folded up and down. Possible states Passenger foot pegs folded up –...

  • Page 45: Shift Lever

    CONTROLS 6 6.19 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11...

  • Page 46: Foot Brake Lever

    6 CONTROLS 6.20 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10 6.21 Side stand The side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle.
  • Page 47 CONTROLS 6 Side stand folded in – This position is mandatory when riding • the motorcycle. The safety starting system is inactive.

  • Page 48: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument The combination instrument is attached in front of the handlebar. Indicator lamps ( p. 52) Display ( p. 56) Function buttons ( p. 59) E01184-10...

  • Page 49: Activation And Test

    The malfunction indicator lamp always lights up as long as E01185-10 the engine is not running. If the engine is running and the malfunction indicator lamp lights up, stop (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop.

  • Page 50: Warnings

    7 COMBINATION INSTRUMENT Warnings Info All warnings that have occurred are shown automatically in succession on the display until they are no longer active. As soon as an error occurs, the relevant indicator lamps light up to signal that an indication/warning note for the operating safety has been detected.
  • Page 51 COMBINATION INSTRUMENT 7 Side Stand Down appears on the display if the side stand is folded down. Clutch Switch Failure appears on the display if the clutch switch is faulty. F01485-01 Transport Lock appears on the display if transport mode is acti- vated.
  • Page 52 7 COMBINATION INSTRUMENT Low Oil Pressure appears on the display if the oil pressure is too low. Low Battery appears on the display if the battery voltage falls below the specified value. ≤ 10.5 V Battery voltage F01477-03 Coolant Sensor Failure appears on the display if the coolant temper- ature sensor is faulty.
  • Page 53 COMBINATION INSTRUMENT 7 Fuel Level Sensor Failure appears on the display if the fuel level indicator is faulty. Low Fuel Level appears on the display if the fuel level reaches the reserve mark. F01477-05...

  • Page 54: Indicator Lamps

    – The turn signal is switched on. Malfunction indicator lamp lights up yellow – The E01187-01 OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.
  • Page 55 COMBINATION INSTRUMENT 7 The shift warning lights up/flashes red – The shift warning light flashes red when the set shift speed RPM1 is reached. The shift warning light lights up red when the set shift speed RPM2 is reached. The idle indicator lamp lights up green – The trans- mission is in neutral.

  • Page 56: Shift Warning Light

    7 COMBINATION INSTRUMENT Shift warning light The shift warning light is located in the center above the dis- play. Info The shift warning light can be configured in the Trip 1 display and Trip 2 display by keeping the MODE button pressed. The shift warning light is always active during the running-in phase (up to 1,000 km / 621 mi).
  • Page 57 COMBINATION INSTRUMENT 7 Coolant temperature > 35 °C (> 95 °F) > 1,000 km (> 620 mi) RPM1 shift warning flashes light RPM2 shift warning lights up light...

  • Page 58: Display

    7 COMBINATION INSTRUMENT Display The tachometer shows the engine speed in revolutions per minute. The gear display shows the engaged gear. is shown in kilometers per hour km/h or in miles per Speed hour mph. The fuel level display is displayed in the area.

  • Page 59: Fuel Level Display

    COMBINATION INSTRUMENT 7 Fuel level display The fuel tank contents are shown in area of the display. The fuel level indicator consists of bars. The more bars are lit, the more fuel is in the fuel tank. Info If the fuel level is getting low, the warning Low Fuel Level will also appear on the display.

  • Page 60: Coolant Temperature Indicator

    7 COMBINATION INSTRUMENT Coolant temperature indicator The coolant temperature display is shown in segment of the display. The coolant temperature indicator consists of bars. The more bars that light up, the hotter the coolant. Note Engine failure Overheating damages the engine. –...

  • Page 61: Function Buttons

    COMBINATION INSTRUMENT 7 Engine hot – Eleven to thirteen bars light up. • Engine very hot – All thirteen bars light up. • Function buttons Press the MODE button to change display modes. Possible display modes are TRIP F (after reaching the fuel reserve level), total distance traveled (ODO), distance 1 (TRIP 1), distance 2 (TRIP 2) and ABS mode (ABS).

  • Page 62: Trip F Display

    7 COMBINATION INSTRUMENT 7.10 TRIP F display – Press the MODE button briefly and repeatedly until TRIP F appears on the display. TRIP F shows the distance traveled since the fuel reserve level was reached. Info When the fuel level reaches the reserve mark, the warn- ing Low Fuel Level appears on the display.

  • Page 63: Odo Display

    COMBINATION INSTRUMENT 7 7.11 ODO display – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered. Info This value is retained, even if the 12-V battery is discon- nected from the vehicle or the fuse blows. Press the Next menu on the display F01469-01...

  • Page 64: Trip 1 Display

    7 COMBINATION INSTRUMENT 7.12 TRIP 1 display – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. TRIP 1 shows the distance since the last reset, such as between two refueling stops. TRIP 1 is always running and counts up to 9999.9.

  • Page 65: Trip 2 Display

    COMBINATION INSTRUMENT 7 7.13 TRIP 2 display – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. TRIP 2 shows the distance since the last reset, such as between two refueling stops. TRIP 2 is always running and counts up to 9999.9.

  • Page 66: Riding Time/Average Speed Menu

    7 COMBINATION INSTRUMENT 7.14 riding time/average speed menu – Press the SET button briefly and repeatedly until the desired menu appears. The riding time and average speed are displayed in this menu. Press the Next menu on the display SET button briefly.

  • Page 67: Average Fuel Consumption 1/Average Fuel Consumption 2 Menu

    COMBINATION INSTRUMENT 7 Press the Next menu on the display SET button briefly. Press the Next display mode on the display MODE button briefly. 7.16 average fuel consumption 1/average fuel consumption 2 menu – Press the SET button briefly and repeatedly until the desired menu appears.

  • Page 68: Average Fuel Consumption 2/Service Menu

    7 COMBINATION INSTRUMENT Press the Next display mode on the display MODE button briefly. 7.17 average fuel consumption 2/service menu – Press the SET button briefly and repeatedly until the desired menu appears. The average fuel consumption 2 in km/L (or miles/L) and the distance to the next service are displayed in this menu.

  • Page 69: Service/Range Menu

    COMBINATION INSTRUMENT 7 7.18 service/range menu – Press the SET button briefly and repeatedly until the desired menu appears. This menu shows the distance to the next service and the range. Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank.

  • Page 70: Range/Riding Time Menu

    7 COMBINATION INSTRUMENT 7.19 range/riding time menu – Press the SET button briefly and repeatedly until the desired menu appears. The range and the riding time are displayed in this menu. Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank.
  • Page 71 COMBINATION INSTRUMENT 7 Condition The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE button for 5 seconds. The display changes from km/h to mph or from mph to km/h.

  • Page 72: Setting The Clock

    7 COMBINATION INSTRUMENT 7.21 Setting the clock Info The time is displayed in 24-hour format. The time must be reset if the 12-V battery was disconnected from the vehicle or the fuse was removed. Condition The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display.

  • Page 73: Adjusting The Shift Speed Rpm1

    COMBINATION INSTRUMENT 7 7.22 Adjusting the shift speed RPM1 Condition The motorcycle is stationary. ODO > 1,000 km (621 m). – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. – Press the MODE button for 5 seconds. The RPM1 display appears.

  • Page 74: Adjusting The Shift Speed Rpm2

    7 COMBINATION INSTRUMENT The RPM1 display disappears and the set shift speed RPM1 is adopted and saved. 7.23 Adjusting the shift speed RPM2 Condition The motorcycle is stationary. ODO > 1,000 km (621 m). – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display.

  • Page 75: Adjusting Abs Mode

    COMBINATION INSTRUMENT 7 Info The MODE button increases the value. The SET button decreases the value. – Press the MODE button and SET button simultaneously. The RPM2 display disappears and the set shift speed RPM2 is adopted and saved. 7.24 Adjusting ABS mode Condition The motorcycle is stationary.
  • Page 76 7 COMBINATION INSTRUMENT Info Do not open the throttle during the selection. If switching ABS mode was unsuccessful, the previ- ously set ABS mode will remain active. A flashing ABS mode indicates that the ABS mode dis- played does not match the actual ABS mode due to a malfunction.

  • Page 77: Preparing For Use 8

    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 78 Info When using the vehicle, remember that others may feel disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. The delivery certificate is transferred upon vehicle handover. – Read the entire Owner's Manual before riding for the first time.

  • Page 79: Running In The Engine

    PREPARING FOR USE 8 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) 7,500 rpm Info During the running-in phase, the shift warning light is set to a specified value and cannot be changed. –...
  • Page 80 8 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 The luggage system will be damaged if it is overloaded. –...
  • Page 81 PREPARING FOR USE 8 – If luggage is carried, ensure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. – Do not exceed maximum permissible weight and maximum permissible axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.)

  • Page 82: Riding Instructions

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

  • Page 83: Starting

    RIDING INSTRUCTIONS 9 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 effective exhaust extraction when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis- charged or missing.
  • Page 84 9 RIDING INSTRUCTIONS – Unlock the steering. ( p. 38) – Sit on the vehicle, take the weight off of the side stand, and move it all the way up with your foot. – Turn the emergency OFF switch to the position –...

  • Page 85: Starting Off

    RIDING INSTRUCTIONS 9 Info Do not press the start button until the combination instrument function check has finished. Do not open the throttle to start. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again. This motorcycle is equipped with a safety starting sys- tem.

  • Page 86: Shifting, Riding

    9 RIDING INSTRUCTIONS Shifting, riding. Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – 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 87 RIDING INSTRUCTIONS 9 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 pegs and holds on to the rider or the grab handles. –...
  • Page 88 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 (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop.
  • Page 89 RIDING INSTRUCTIONS 9 – Shift into a higher gear when conditions allow (incline, road situation, etc.). – Release throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info The gear positions can be seen in the figure. The neu- tral or idle position is between the first and second 401950-11 gears.

  • Page 90: 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 91 RIDING INSTRUCTIONS 9 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. –...

  • Page 92: Stopping, Parking

    9 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 93 RIDING INSTRUCTIONS 9 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down. –...

  • Page 94: Transport

    9 RIDING INSTRUCTIONS Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the 12-V battery will dis- charge. You should therefore always switch off the engine with the ignition lock – the emergency OFF switch is intended for emergencies only.

  • Page 95: Refueling

    RIDING INSTRUCTIONS 9 – Switch off the engine and remove the ignition key. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 401448-01 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 96 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.) Note Environmental hazard Improper handling of fuel is a danger to the environment.
  • Page 97 RIDING INSTRUCTIONS 9 – Switch off the engine. – Open the fuel tank filler cap. ( p. 38) – Fill the fuel tank with fuel up to the lower edge of the fuel filler. Total fuel tank 11 l Super unleaded capacity, approx.

  • Page 98: 10 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 99 SERVICE SCHEDULE 10 every 24 months every 12 months every 15,000 km (9,300 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ○ ● ● ● Check the rear brake fluid level. ( p. 131) ○ ● ● ●...

  • Page 100: Recommended Work

    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 interval display.
  • Page 101 SERVICE SCHEDULE 10 every 48 months every 12 months every 30,000 km (18,600 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ● ● Checking the fork bearing for play. ● ● Check the wheel bearing for play. ○...

  • Page 102: 11 Tuning The Chassis

    11 TUNING THE CHASSIS 11.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris- tic. – Ride slowly to start with after making adjustments to get the feel of the new handling characteristic. Info The spring preload defines the initial status of the spring operation on the shock absorber.

  • Page 103: Adjusting The Shift Lever

    TUNING THE CHASSIS 11 11.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. – Loosen nuts – Adjust the shift lever by turning shift rod Guideline Shift rod adjustment 110 … 122 mm (4.33 … range 4.8 in) Info...
  • Page 104 11 TUNING THE CHASSIS Info After the nuts have been tightened, the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells. – Check the shift lever to ensure it is functioning properly and can move freely.

  • Page 105: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with 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 the supports of the lifting gear. –...

  • Page 106: Lifting The Motorcycle With The Front Lifting Gear

    12 SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the vehicle on side stand – Remove bushings kit. 402029-10 12.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over.
  • Page 107 SERVICE WORK ON THE CHASSIS 12 Condition – Remove protection cap K00729-10 – Move the handlebar to the straight-ahead position. Position the lifting gear. Mounting pin (69329965030) Front wheel work stand, large (69329965100) Info Always raise the motorcycle at the rear first. –...

  • Page 108: Taking The Motorcycle Off The Front Lifting Gear

    12 SERVICE WORK ON THE CHASSIS 12.4 Taking the motorcycle off the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Main work – Secure the motorcycle against falling over.

  • Page 109: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 – Mount protection cap K00729-10 Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 103) 12.5 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 110 12 SERVICE WORK ON THE CHASSIS Main work – Push protection caps of both fork legs downward. – Push dust boots of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumu- late behind the dust boots.

  • Page 111: Removing The Passenger Seat

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Take the motorcycle off the front lifting gear. ( p. 106) – Remove the rear of the motorcycle from the lifting gear. p. 103) 12.6 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise.

  • Page 112: Mounting The Passenger Seat

    12 SERVICE WORK ON THE CHASSIS 12.7 Mounting the passenger seat – Attach hooks on the passenger seat to seat mounting on the subframe, and lower it at the rear while pushing for- ward. – Press the passenger seat downward until it clicks into place. Warning Danger of accidents The seat can come loose from the anchoring if it is not mounted correctly.

  • Page 113: Mounting The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 12 Main work – Raise the rear of the front rider's seat, pull it towards the rear, and remove it upwards. H01993-01 12.9 Mounting the front rider's seat Main work – Attach the front rider's seat in area and lower at the rear.

  • Page 114: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS 12.10 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 112) 400678-01 12.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.
  • Page 115 SERVICE WORK ON THE CHASSIS 12 Note 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 116: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.12 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 117: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 115) – Remove the rear of the motorcycle from the lifting gear. p. 103) 12.13 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.
  • Page 118 12 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 5 … 7 mm (0.2 … 0.28 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in...

  • Page 119: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 103) 12.14 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 120 12 SERVICE WORK ON THE CHASSIS – Shift the transmission into neutral. – Pull on the lower chain section with the specified weight Guideline Weight, chain wear measure- 15 kg (33 lb.) ment – Measure distance of 20 chain rollers in the lower chain section.
  • Page 121 SERVICE WORK ON THE CHASSIS 12 – Check the chain sliding guard for wear. » If screw becomes visible in area of the chain slid- ing guard when viewed from above: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. F00752-10 Finishing work –...

  • Page 122: Removing The Front Spoiler

    12 SERVICE WORK ON THE CHASSIS 12.15 Removing the front spoiler – Remove screws – Take off the front spoiler. S04212-10 12.16 Fitting front spoiler – Position the front spoiler. Mount and tighten screws Guideline Screw, front spoiler M6x9 9 Nm (6.6 lbf ft) rear S04212-10...

  • Page 123: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.17 Removing the front fender – Remove screws – Remove the front fender. 307348-10 12.18 Installing the front fender – Position the front fender. – Mount and tighten screws Guideline Screw, front fender 7 Nm (5.2 lbf ft) 307348-10...

  • Page 124: 13 Brake System

    Do not make any changes to the suspension travel. – 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. – Maintain specified tire pressure. –...
  • Page 125 BRAKE SYSTEM 13 Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations. It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.

  • Page 126: Checking The Brake Discs

    ABS warning lamp goes out after starting off. 13.2 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.)
  • Page 127 BRAKE SYSTEM 13 – Check the front and rear brake disc thickness at multiple points for the dimension Info Wear will reduce the thickness of the brake disc at con- tact surface of the brake linings. Brake discs - wear limit front 4.5 mm (0.177 in) 400480-10...

  • Page 128: Checking The Front Brake Fluid Level

    – 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.) – Move the brake reservoir mounted on the handlebar into a hori- zontal position.

  • Page 129: 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 130 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.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 131 BRAKE SYSTEM 13 Main work – Move the brake reservoir mounted on the handlebar into a hori- zontal position. – Remove screws – Take off cover with membrane – Add brake fluid to level Guideline 5 mm (0.2 in) Dimension C00201-10 Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 132: 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 133: Checking The Rear Brake Fluid Level

    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.) – Position the vehicle upright.

  • Page 134: 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.) Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 135 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.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 136 13 BRAKE SYSTEM Condition The screw cap is locked. – Remove screw and take off the screw cap lock. H01142-10 – Position the vehicle upright. – Remove screw cap with membrane – Add brake fluid up to the marking Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 137: 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 138: Checking The Free Travel Of Foot Brake Lever

    13 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 139 BRAKE SYSTEM 13 – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...

  • Page 140: Adjusting The Free Travel Of The Foot Brake Lever

    13 BRAKE SYSTEM 13.10 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
  • Page 141 BRAKE SYSTEM 13 – Detach spring – Release nut and use screw to adjust the specified free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) Info The range of adjustment is limited. –...

  • Page 142: 14 Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 103) – Lift the motorcycle with the front lifting gear. ( p. 104) Main work – Remove screws and push the fender to the side. –...

  • Page 143: Installing The Front Wheel

    WHEELS, TIRES 14 Info Do not actuate the hand brake lever when the front wheel is removed. 14.2 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. –...
  • Page 144 14 WHEELS, TIRES – Clean the thread of the wheel spindle and screw – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel 25 Nm (18.4 lbf ft) spindle –...

  • Page 145: Removing Rear Wheel

    WHEELS, TIRES 14 Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Remove the rear of the motorcycle from the lifting gear. p. 103) 14.3 Removing rear wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.
  • Page 146 14 WHEELS, TIRES Main work – Remove screw and pull wheel speed sensor out of the hole. – Remove nut and washer. – Remove chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster –...

  • Page 147: Installing The Rear Wheel

    WHEELS, TIRES 14 14.4 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 148 14 WHEELS, TIRES – Clean and grease the wheel spindle. Long-life grease ( p. 228) – Clean the contact areas on the brake caliper bracket and link fork. – Mount the damping rubber and rear sprocket carrier on the rear wheel. –...
  • Page 149 WHEELS, TIRES 14 – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Guideline Mount left and right chain adjusters in the same posi- tion. – Mount nut and the washer. – Push the rear wheel forward so that the chain adjusters are in contact with the screws, and tighten nut Guideline In order for the rear wheel to be correctly aligned, the mark-...

  • Page 150: Checking Rear Hub Damping Rubber Pieces

    14 WHEELS, TIRES – Check the chain tension. ( p. 114) 14.5 Checking rear hub damping rubber pieces Info The engine power is transmitted from the rear sprocket to the rear wheel via the 6 damping rubber pieces. They eventually wear out during operation. If the damping rubber pieces are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
  • Page 151 WHEELS, TIRES 14 – Lay the rear wheel on a workbench with the rear sprocket fac- ing upward and insert the wheel spindle in the hub. – To check play , hold the rear wheel tight and try to rotate the rear sprocket.

  • Page 152: 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 153 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...

  • Page 154: Checking Tire Pressure

    14 WHEELS, TIRES » If the tires are more than 5 years old: – Change the tires. 14.7 Checking tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximum tire service life. –...

  • Page 155: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.
  • Page 156 15 ELECTRICAL SYSTEM Main work – Disconnect negative cable from the 12-V battery. V01273-10 – Pull back positive terminal cover – Disconnect positive cable from the 12-V battery. – Detach rubber strap – Pull the 12-V battery upwards and out of the battery compart- ment.

  • Page 157: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 15.2 Installing the 12-V battery Main work – Position the 12-V battery in the battery compartment. Guideline The terminals of the battery must face upwards. 12-V battery (ETZ-9-BS) ( p. 216) – Attach rubber strap – Position positive cable and mount and tighten the screw.

  • Page 158: Charging The 12-V Battery

    15 ELECTRICAL SYSTEM – Set the clock. ( p. 70) 15.3 Charging the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. –...
  • Page 159 ELECTRICAL SYSTEM 15 Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety valves.
  • Page 160 15 ELECTRICAL SYSTEM Main work – Connect a battery charger to the 12-V battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the open- circuit voltage, the starting ability of the 12-V battery, and the alternator.

  • Page 161: Changing The Abs Fuses

    ELECTRICAL SYSTEM 15 Finishing work – Mount the front rider's seat. ( p. 111) – Mount the passenger seat. ( p. 110) – Set the clock. ( p. 70) 15.4 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. –...
  • Page 162 15 ELECTRICAL SYSTEM To change the fuse of the ABS hydraulic unit: – Take off the protection cap and remove fuse Info A faulty fuse has a burned-out fuse wire Warning Fire hazard Incorrect fuses overload the electrical S04216-10 system. – Only use fuses with the required ampere value.
  • Page 163 ELECTRICAL SYSTEM 15 To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. S04216-11 –...

  • Page 164: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the pas- senger seat. Preparatory work – Remove the passenger seat. ( p.
  • Page 165 ELECTRICAL SYSTEM 15 Main work – Open fuse box cover Info Fuse 1 (main fuse) is located in its own fuse box. – Remove the faulty fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 10 A - combination instrument Fuse 3 - 10 A - power relay Fuse 4 - 15 A - ignition coil, fuel pump relay, starter relay, horn...
  • Page 166 15 ELECTRICAL SYSTEM Info A faulty fuse has a burned-out fuse wire Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert the spare fuse with the correct rating. Fuse (75011088010) ( p.

  • Page 167: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 15.6 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...
  • Page 168 15 ELECTRICAL SYSTEM – Remove protection cap – Unplug connector K00793-10 – Detach retaining clamp – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Guideline Insert the headlight bulb so that the holding lugs latch into the recesses.
  • Page 169 ELECTRICAL SYSTEM 15 – Plug in connector – Mount protection cap – Swivel the headlight mask upward. K00793-10 – Mount screw Info Screw also secures the headlight. Ensure the screw is always screwed in far enough. – Check that the lighting is functioning properly. S04238-10 Finishing work –...

  • Page 170: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 15.7 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. – Make another mark at a distance under the first marking.

  • Page 171: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 15.8 Adjusting the headlight range 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. If you have a payload, you may have to correct the headlight range.
  • Page 172 15 ELECTRICAL SYSTEM – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Press bulb carefully into the socket, turn it counterclock- wise by about 30°, and take it out of the socket. Guideline Do not touch the reflector with your fingers and keep it free from grease.

  • Page 173: Diagnostics Connector

    ELECTRICAL SYSTEM 15 15.10 Diagnostics connector Diagnostics connector is located under the passenger seat. S04236-10 15.11 Front ACC1 and ACC2 Installation location – Power supplies ACC1 and ACC2 front are located behind the left side beneath the fuel tank. S04237-10...

  • Page 174: 16 Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .
  • Page 175 COOLING SYSTEM 16 The coolant is cooled by the air stream and a radiator fan which is activated at high temperature. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. Info If the cooling system overheats, the maximum engine speed is limited.

  • Page 176: Checking The Coolant Level

    16 COOLING SYSTEM 16.2 Checking the coolant level 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 177 COOLING SYSTEM 16 – Stand the motorcycle upright on a horizontal surface. – Check the coolant level in the compensating tank The coolant level must be between MIN and MAX. » If the coolant level does not match the specified value: –...

  • Page 178: Checking The Antifreeze And Coolant Level

    16 COOLING SYSTEM 16.3 Checking the antifreeze and coolant level 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 179 COOLING SYSTEM 16 – Stand the motorcycle upright on a horizontal surface. – Remove the cap of the compensating tank – Check the coolant antifreeze. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...
  • Page 180 16 COOLING SYSTEM – Remove radiator cap – Check the coolant antifreeze. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: – Correct the coolant antifreeze. – Check the coolant level in the radiator.

  • Page 181: Draining The Coolant

    COOLING SYSTEM 16 16.4 Draining the coolant 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 182: Filling/Bleeding The Cooling System

    16 COOLING SYSTEM Main work – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw with the seal ring. – Remove the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
  • Page 183 COOLING SYSTEM 16 Main work – Remove radiator cap E01179-11 – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immedi- ately.
  • Page 184 16 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 185: Changing The Coolant

    COOLING SYSTEM 16 16.6 Changing the coolant 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 186 16 COOLING SYSTEM Main work – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw with the seal ring. – Remove the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
  • Page 187 COOLING SYSTEM 16 – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in the coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately.
  • Page 188 16 COOLING SYSTEM – Stop the engine and allow it to cool down. – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Remove the cap of compensating tank and top up the coolant level up to the MAX marking.

  • Page 189: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable 3 …...

  • Page 190: Adjusting Throttle Cable Play

    17 TUNING THE ENGINE 17.2 Adjusting throttle cable play – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the throttle cable play with barrel adjuster Guideline Throttle cable play 3 … 5 mm (0.12 … 0.2 in) –...
  • Page 191 TUNING THE ENGINE 17 – Check the clutch lever for smooth operation. – Move the handlebar to the straight-ahead position. – Pull the clutch lever until resistance is perceptible, and deter- mine the play in the clutch lever 1 … 3 mm (0.04 … Clutch lever play 0.12 in) »...

  • Page 192: Adjusting Play In The Clutch Lever

    17 TUNING THE ENGINE 17.4 Adjusting play in the clutch lever – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the clutch level by turning adjusting screw Guideline 1 …...

  • Page 193: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 18.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.

  • Page 194: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    18 SERVICE WORK ON THE ENGINE 18.2 Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
  • Page 195 SERVICE WORK ON THE ENGINE 18 Main work – Place an appropriate container under the engine. – Remove oil drain plug with the O-ring. – Remove oil screen with the O-ring. – Allow the engine oil to drain completely. – Clean the oil drain plug and the oil screen thoroughly.
  • Page 196 18 SERVICE WORK ON THE ENGINE – Insert new oil filter – Oil the O-ring of the oil filter cover. Mount oil filter cover – Mount and tighten screws Guideline Screw, oil filter cover 10 Nm (7.4 lbf ft) Info Too little engine oil or poor-quality engine oil will result S04244-10 in premature wear of the engine.

  • Page 197: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 198 18 SERVICE WORK ON THE ENGINE Main work – Remove filler plug with the O-ring, and fill up with engine oil. Engine oil (SAE 15W/50) ( p. 226) Engine oil (SAE 10W/40) ( p. 227) Info In order to achieve optimal engine oil performance, it is 401955-10 not advisable to mix different engine oils.
  • Page 199 SERVICE WORK ON THE ENGINE 18 Finishing work – Check the engine oil level. ( p. 191)

  • Page 200: 19 Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the 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 201 CLEANING, CARE 19 – Close off exhaust system to keep water from entering. – Remove loose dirt first with a soft jet of water. – Spray the heavily soiled parts with a normal commercial motor- cycle cleaner and clean using a brush. Motorcycle cleaner ( p.
  • Page 202 19 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 sleeves of the handlebar controls to allow any water that has penetrated to evaporate.

  • Page 203: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 – Treat all 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. 229) – Lubricate the ignition and steering lock. Universal oil spray ( p.
  • Page 204 19 CLEANING, CARE – Clean the motorcycle. ( p. 198) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly clean the motorcycle and, in particular, the brake calipers and brake linings, after they have cooled down and without removing them, with cold water and dry carefully.

  • Page 205: Storage 20

    STORAGE 20 20.1 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 206 – Store vehicle in a dry location that is not subject to large fluc- tuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 103) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 207: Preparing For Use After Storage

    STORAGE 20 20.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 106) – Remove the rear of the motorcycle from the lifting gear. p. 103) – Install the 12-V battery. p. 155) –...

  • Page 208: 21 Troubleshooting

    Carry out start procedure. ( p. 81) – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Engine has too little power Air filter is very dirty Change the air filter. –...
  • Page 209 Check the radiator fan system. – Malfunction indicator lamp Malfunction in the electronic Read out the fault memory using the lights up yellow fuel injection KTM diagnostics tool. – Engine dies during the trip Lack of fuel Refuel. ( p. 93) –...
  • Page 210 21 TROUBLESHOOTING Faults Possible cause Action – Turn signal, brake light, and Fuse 6 blown Change the fuses of individual power horn are not functional consumers. ( p. 162) – Time is not (correctly) dis- Fuse 8 is blown Change the fuses of individual power played consumers.

  • Page 211: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 200 cm³ (12.2 cu in) Stroke 49 mm (1.93 in) Bore 72 mm (2.83 in) Compression ratio 11,5:1 Control DOHC, 4 valves controlled via cam lever, chain drive Intake valve diameter 28.5 mm (1.122 in) Exhaust valve diameter 24 mm (0.94 in)

  • Page 212: Engine Tightening Torques

    22 TECHNICAL DATA Transmission ratio 1st gear 12:34 2nd gear 15:31 3rd gear 18:28 4th gear 21:26 5th gear 22:23 6th gear 24:22 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 230 W Spark plug BOSCHVR5NEU Spark plug electrode gap...
  • Page 213 TECHNICAL DATA 22 Screw, engine vent plate 7 Nm (5.2 lbf ft) Loctite ® 243™ Screw, retaining bracket 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket, stator 8 Nm (5.9 lbf ft) Loctite ® 243™ cable Screw, stator 8 Nm (5.9 lbf ft) Loctite ®...
  • Page 214 22 TECHNICAL DATA Screw, engine case M6x60 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, engine sprocket 12 Nm (8.9 lbf ft) Screw, freewheel gear retaining 12 Nm (8.9 lbf ft) Loctite ® 243™ bracket Screw, locking lever 12 Nm (8.9 lbf ft) Loctite ®...
  • Page 215 TECHNICAL DATA 22 Nut, exhaust flange 8 Nm (5.9 lbf ft) Screw, balancer shaft gear wheel 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, camshaft gear wheel 32 Nm (23.6 lbf ft) Loctite ® 243™ Screw, shift mechanism return 20 Nm (14.8 lbf ft) Loctite ®...

  • Page 216: Capacities

    22 TECHNICAL DATA Nut, drive gear wheel for balancer 60 Nm (44.3 lbf ft) Loctite ® 243™ shaft 22.3 Capacities 22.3.1 Engine oil Engine oil 1.5 l (1.6 qt.) Engine oil (SAE 15W/50) Ambient temperature: 0 … 50 °C p. 226) (32 …...

  • Page 217: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Lattice frame of steel tubes, powder-coated WP Suspension Fork WP Suspension Shock absorber Brake system front Disc brake with 4-piston brake caliper rear Disc brake with single-pot brake caliper, floating Brake discs - diameter front 300 mm (11.81 in) rear...

  • Page 218: Electrical System

    22 TECHNICAL DATA Steering head angle 65° Wheelbase 1,367 ± 15 mm (53.82 ± 0.59 in) Seat height, unloaded 800 mm (31.5 in) Dry weight 129.5 kg (285.5 lb.) Maximum permissible front axle load 125 kg (276 lb.) Maximum permissible rear axle load 210 kg (463 lb.) Maximum permissible overall weight 335 kg (739 lb.)

  • Page 219: Tires

    110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF REVZ‑FC MRF REVZ‑C The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork article number F20123401O Fork...

  • Page 220: Shock Absorber

    22 TECHNICAL DATA 22.8 Shock absorber Shock absorber article number S20120801O WP Suspension Shock absorber Spring preload Standard 3 clicks Fitted length 307 mm (12.09 in) 22.9 Chassis tightening torques Screw, chain guard EJOT PT ® K60x30 7 Nm (5.2 lbf ft) Remaining screws, chassis 4 Nm (3 lbf ft) Remaining nuts, chassis...
  • Page 221 TECHNICAL DATA 22 Screw, tail light 5 Nm (3.7 lbf ft) Nut, foot brake lever adjustment 9 Nm (6.6 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ABS hose clamp 7 Nm (5.2 lbf ft) Screw, ABS module 10 Nm (7.4 lbf ft)
  • Page 222 22 TECHNICAL DATA Screw, front spoiler rear M6x9 9 Nm (6.6 lbf ft) Screw, fuel pump 10 Nm (7.4 lbf ft) Screw, fuel tank cover 5 Nm (3.7 lbf ft) Screw, fuel tank cover 7 Nm (5.2 lbf ft) Screw, headlight 8 Nm (5.9 lbf ft) Screw, holder of fuel vapor valve 9 Nm (6.6 lbf ft)
  • Page 223 TECHNICAL DATA 22 Screw, rear wheel speed sensor 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, shift lever linkage 11 Nm (8.1 lbf ft) Loctite ® 243™ Screw, side stand sensor cable 9 Nm (6.6 lbf ft) Loctite ® 243™...
  • Page 224 22 TECHNICAL DATA Screw, fuel tank 20 Nm (14.8 lbf ft) Screw, grab handle 22 Nm (16.2 lbf ft) Screw, handlebar clamp 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, horn 12 Nm (8.9 lbf ft) Screw, main silencer 23 Nm (17 lbf ft) Screw, passenger footrest unit 22 Nm (16.2 lbf ft)
  • Page 225 TECHNICAL DATA 22 Fitting, shock absorber, bottom M10x1.25 51 Nm (37.6 lbf ft) Loctite ® 243™ Nut, left rear mirror M10x1.25 16 Nm (11.8 lbf ft) Nut, right rear mirror M10LHx1.25 16 Nm (11.8 lbf ft) Nut, side stand bracket M10x1.25 35 Nm (25.8 lbf ft) Screw, combination instrument...
  • Page 226 22 TECHNICAL DATA Nut, steering head M30x1 1st stage 45 Nm (33.2 lbf ft) 2nd stage (loosen, counterclock- wise) 2 turns 3rd stage 5 Nm (3.7 lbf ft)

  • Page 227: Substances 23

    SUBSTANCES 23 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 228 23 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 229 SUBSTANCES 23 Engine oil (SAE 10W/40) Standard/classification – JASO T903 MA2 ( p. 230) – SAE ( p. 230) (SAE 10W/40) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

  • Page 230: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX...
  • Page 231 AUXILIARY SUBSTANCES 24 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 ® – Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX ®...

  • Page 232: 25 Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 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 233: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 Anti-lock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 234: 27 List Of Abbreviations

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

  • Page 235: List Of Symbols 28

    Malfunction indicator lamp lights up yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The general warning lamp flashes yellow – A note/warning note on operating safety has been detected.

  • Page 236: Index

    INDEX INDEX Brake discs 12-V battery checking ......124 charging ......156 Brake fluid installing .
  • Page 237 INDEX Chain tension TRIP F display ..... . . 60 adjusting ......115 warnings .
  • Page 238 INDEX Engine sprocket removing ......140 checking ......117 Fuel tank filler cap Environment .
  • Page 239 INDEX Indicator lamps ......52 Oil screen Intended use ......10 cleaning .
  • Page 240 INDEX Rear wheel Steering installing ......145 locking ......37 removing .
  • Page 241 INDEX Tire condition checking ......150 Tire pressure checking ......152 Tool set .
  • Page 242 *3214156en* 3214156en 04/2020 KTM Sportmotorcycle GmbH Photo: 5230 Mattighofen/Austria Mitterbauer/KISKA/KTM http://www.ktm.com...

This manual is also suitable for:

F4175t2F4175t3:

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