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KTM 450 Rally Factory Replica 2021 Owner's Manual

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OWNER'S MANUAL
2021
450 RALLY Factory Replica
Art. no. 3214230en

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Summary of Contents for KTM 450 Rally Factory Replica 2021

  • Page 1 OWNER'S MANUAL 2021 450 RALLY Factory Replica Art. no. 3214230en...
  • 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: Table Of Contents

    TABLE OF CONTENTS 6.18 Foot brake lever ....... 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.19 Side stand........21 Symbols used ........6 6.20 Steering lock ........22 Formats used........6 6.21 Locking the steering ......22 SAFETY ADVICE..........7 6.22 Unlocking the steering......
  • Page 5 TABLE OF CONTENTS Transporting ........40 12.12 Adjusting the steering head bearing play ..........62 Refueling ........40 12.13 Greasing the steering head 10 SERVICE SCHEDULE ........42 bearing ........64 12.14 Removing the shock absorber ..64 10.1 Additional information ...... 42 12.15 Installing the shock absorber ..
  • Page 6 TABLE OF CONTENTS 13.2 Checking brake discs......90 18 SERVICE WORK ON THE ENGINE ....121 13.3 Checking the front brake fluid level ... 91 18.1 Checking the engine oil level... 121 13.4 Adding the front brake fluid ... 91 18.2 Changing the engine oil and oil 13.5...
  • Page 7 TABLE OF CONTENTS 30.3 Green and blue symbols....171 INDEX ............. 172...

  • Page 8: Means Of Representation

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

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of racing. The motor- cycles comply with the currently valid regulations and categories of the top international motorsport organizations.

  • Page 10: Safe Operation

    – 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 suitable pro- tective clothing.

  • Page 11: Work Rules

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 12: Important Notes

    Manufacturer warranty, 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 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left A00454-10 Clutch lever ( p. 15) Seat release strap Side stand ( p. 21) Shift lever ( p. 21)

  • Page 14: View Of Vehicle, Rear Right Side

    4 VIEW OF VEHICLE View of vehicle, rear right side A00455-10 Fuel pump switch ( p. 17) Stop button ( p. 15) Light switch ( p. 16) Turn signal switch ( p. 16) Horn button ( p. 16) Start button ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is embossed in the steering head on the right. 401945-10 Type label The type label is located on the steering head on the left. A00441-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 16: Fork Part Number

    5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number The shock absorber article number is located on the left side of the shock absorber compensating tank. H03307-10...

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. L03000-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 18: Light Switch

    6 CONTROLS Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central posi- tion. In this position, the low beam and tail light are switched on. High beam on –...

  • Page 19: Emergency Off Switch

    A00402-10 Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. 6.11 Fuel pump switch The fuel pump switch is fitted on the left side of the handle- bar.

  • Page 20: Fuel Tank

    6 CONTROLS 6.12 Fuel tank This model has three separate fuel tanks controlled by a fuel pump switch. Two fuel tanks are located in front of the seat and one fuel tank is located beneath the seat. The right fuel tank is filled via fuel tank filler cap and the left fuel tank is filled via fuel tank filler cap A00735-10...

  • Page 21: Closing Fuel Tank Filler Caps

    CONTROLS 6 – Turn fuel tank filler caps counterclockwise and lift off. A00736-10 6.14 Closing fuel tank filler caps – Mount fuel tank filler caps , and and turn clock- wise until the fuel tanks are tightly closed. Info Route fuel tank breather hoses without kinks.

  • Page 22: Cold Start Button

    6 CONTROLS 6.15 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 23: Shift Lever

    CONTROLS 6 6.17 Shift lever The 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 6.18 Foot brake lever Foot brake lever...

  • Page 24: Steering Lock

    6 CONTROLS The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.20 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 25: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. A00403-10 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 26: Adjusting Combination Instrument Function

    7 COMBINATION INSTRUMENT – Wait 3–5 seconds The settings are stored. Info If no button is actuated for 10-12 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the Setup menu is closed.

  • Page 27: Setting Clock

    COMBINATION INSTRUMENT 7 Setting clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust hour display with the button and/or button –...

  • Page 28: Display Mode Speed (Speed)

    7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 29: Adjusting The Unit Of Measurement

    COMBINATION INSTRUMENT 7 Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically stored. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 30: Display Mode Speed/Clk (Time)

    7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 31: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 32: Display Mode Speed/Tr1 (Trip Master 1)

    7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 33: Display Mode Speed/A1 (Average Speed 1)

    COMBINATION INSTRUMENT 7 Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 34: Display Mode Speed/S1 (Stop Watch 1)

    7 COMBINATION INSTRUMENT Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 35: Table Of Functions

    COMBINATION INSTRUMENT 7 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3–5 sec- Wait 10–12 for 2–3 the button for 2–3 the button onds seconds seconds. seconds. Display mode The display Next display No function No function SPEED/H (oper-...

  • Page 36: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3–5 sec- Wait 10–12 for 2–3 the button for 2–3 the button onds seconds seconds. seconds. Display mode Clears the Next display Reduces Reduces SPEED/TR2 (trip values TR2 mode value of TR2.

  • Page 37: Preparing For Use 8

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 38: Running In The Engine

    8 PREPARING FOR USE – Adjust the free travel of the foot brake lever. p. 96) – Adjust the basic position of the shift lever. p. 120) – Get used to the handling characteristic of the motorcycle on a suitable terrain before undertaking a more chal- lenging trip.

  • Page 39: Riding Instructions 9

    RIDING INSTRUCTIONS 9 Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.

  • Page 40: Starting Off

    Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off and for steep inclines. –...

  • Page 41: Braking

    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 Moisture and dirt impair the brake system.

  • Page 42: Transporting

    9 RIDING INSTRUCTIONS 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. –...
  • Page 43 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 44: 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 45: Recommended Work

    Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Reading out the fault memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make a service entry in KTM Dealer.net.
  • Page 46 10 SERVICE SCHEDULE every 48 months every 12 months after every race Every 100 operating hours Every 50 operating hours Every 40 operating hours After 20 operating hours ● Perform major engine service (Change piston. Check/measure the cylinder. Check the cylinder head. Change the valves, valve springs, and valve spring seats.

  • Page 47: Tuning The Chassis 11

    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 compression adjuster can be seen in slow to normal compression of the shock absorber.

  • Page 48: 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 compression adjuster can be seen in fast compression of the shock absorber.

  • Page 49: 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 50: Checking Riding Sag Of The Shock Absorber

    11 TUNING THE CHASSIS – Measure dimension of rear wheel unloaded. ( p. 47) – Hold the motorcycle perpendicular with the aid of an assistant. – Measure the distance between the rear axle and the fixed point again. – Note down the value as dimension Info The static sag is the difference between measurements...

  • Page 51: Adjusting The Spring Preload 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 Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 52: Adjusting The Riding Sag

    11 TUNING THE CHASSIS – Remove motorcycle from the lift stand. ( p. 55) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Fold out the side stand and secure it. –...

  • Page 53: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 11 11.11 Checking the basic setting of the fork Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, small differences in the rider's weight can be compensated by the spring preload. –...

  • Page 54: Handlebar Position

    11 TUNING THE CHASSIS – Take off protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn counterclockwise by the number of clicks corresponding 402496-10 to the fork type.

  • Page 55: Adjusting The Handlebar Position

    TUNING THE CHASSIS 11 11.15 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...
  • Page 56 11 TUNING THE CHASSIS Info The elastomers are available in different versions. – Mount screws and tighten evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the installed gaps are even.

  • Page 57: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Use the engine guard underneath the engine to raise the vehi- cle.

  • Page 58: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Remove fork protector. ( p. 56) Main work – Push dust boots of both fork legs downward.

  • Page 59: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 12.6 Installing the fork protector – Position fork protector on the right fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 60: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work – Position fork legs. Bleeder screws are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.
  • Page 61 SERVICE WORK ON THE CHASSIS 12 – Remove screws and take off the cable guide. A00471-10 – Remove screws . Take off the handlebar clamps with the rubber washers and elastomers. – Fix handlebar onto the instrument support with cable tie(s) –...

  • Page 62: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 166) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 63 SERVICE WORK ON THE CHASSIS 12 – Position the cable guide. – Mount and tighten screws Guideline Screw, brake line 2 Nm (1.5 lbf ft) holder on bottom triple clamp – Secure the brake line with cable tie F02430-10 – Tighten screw Guideline Screw, top steering...

  • Page 64: Checking Steering Head Bearing Play

    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 65 SERVICE WORK ON THE CHASSIS 12 – Loosen screws – Remove screw A00476-11 – Loosen and retighten screw Guideline Screw, top steering M20x1 12 Nm (8.9 lbf ft) head – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

  • Page 66: Greasing The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS – Remove motorcycle from the lift stand. ( p. 55) 12.13 Greasing the steering head bearing – Remove the lower triple clamp. p. 58) – Install the lower triple clamp. p. 60) H02387-01 12.14 Removing the shock absorber Preparatory work –...

  • Page 67: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12 – Remove screw with the washer. L03051-10 – Remove shock absorber toward top carefully. L03052-10 12.15 Installing the shock absorber Main work – Carefully position shock absorber into the vehicle from above. L03053-10 – Mount and tighten screw with the washer.

  • Page 68: Removing Front Fender

    12 SERVICE WORK ON THE CHASSIS – Raise rear fuel tank L03056-10 – Mount and tighten screws Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis F02403-11 Finishing work – Install the main silencer. ( p. 70) – Mount the seat. ( p.

  • Page 69: Removing The Seat

    SERVICE WORK ON THE CHASSIS 12 12.18 Removing the seat – Pull on loop . At the same time, lift the seat at the rear and take it off. A00740-10 12.19 Mounting the seat – Position the seat between the two front fuel tanks. –...

  • Page 70: Removing The Air Filter

    12 SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 71: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 166) Info Only press the air filter to dry it, never wring it out. –...

  • Page 72: Removing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.25 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...

  • Page 73: Removing Front Left Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 Main work – Drill out all rivets on the main silencer and remove steel strips. Carefully remove rivets in inward direction. Info Remove all remains of rivets from the inside of the main silencer. –...
  • Page 74 12 SERVICE WORK ON THE CHASSIS Main work – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! – Disconnect the quick release coupling and remove it from the holder.

  • Page 75: Removing Front Right Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 12.29 Removing front right fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 76: Installing The Front Left Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Pull off fuel tank breather hose – Remove screws – Take off the fuel tank. Info Set the fuel tank down in an upright position as other- wise fuel can escape from the fuel tank breather at the fuel tank filler cap.

  • Page 77: Installing The Front Right Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 – Mount the seat. ( p. 67) 12.31 Installing the front right fuel tank Main work – Position fuel tank, and mount and tighten screws Guideline Screw, front fuel tank M8 8 Nm (5.9 lbf ft) –...
  • Page 78 12 SERVICE WORK ON THE CHASSIS 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. –...

  • Page 79: Checking The Chain For Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12 12.33 Checking the chain for dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 77) 400678-01 12.34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.

  • Page 80: Checking Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.35 Checking 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 81: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 7 mm Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks .
  • Page 82 12 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.

  • Page 83: Checking The Frame

    SERVICE WORK ON THE CHASSIS 12 – Check chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »...

  • Page 84: Checking Swingarm

    If the link fork shows signs of damage, cracking, or defor- mation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. L03161-10 12.40 Checking the throttle cable routing Preparatory work –...

  • Page 85: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 12.41 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Rubber grip adhesive (00062030051) ( p.
  • Page 86 12 SERVICE WORK ON THE CHASSIS – Remove screw – Take off fuel pump controller and hang to the side. L03162-10 – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar to a horizontal position. – Remove screws –...

  • Page 87: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...

  • Page 88: Removing Side Cover

    12 SERVICE WORK ON THE CHASSIS – Disconnect plug-in connector – Disconnect quick release coupling – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 164) – On the slave cylinder, remove bleeder screw and mount bleeding syringe L03088-10...

  • Page 89: Mounting Side Cover

    SERVICE WORK ON THE CHASSIS 12 Main work – Disconnect plug-in connectors of the turn signals. – Remove screws A00483-10 – Remove screws – Unlock quick releases – Carefully push the side cover to the rear and remove. A00746-10 12.46 Mounting side cover –...

  • Page 90: Removing Front Fairing

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws – Join plug-in connection of the turn signals. A00483-11 12.47 Removing front fairing – Unlock quick releases – Raise the front fairing, tilt forward and take off. A00750-10 12.48 Mounting front fairing –...

  • Page 91: Installing The Engine Guard

    SERVICE WORK ON THE CHASSIS 12 12.50 Installing the engine guard – Position the engine guard. – Mount and tighten screws Guideline Screw, engine guard 25 Nm (18.4 lbf ft) A00749-10...

  • Page 92: 13 Brake System

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

  • Page 93: 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 fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 94: 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 95: Changing The Brake Linings Of The Front Brake

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 96 13 BRAKE SYSTEM 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 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.

  • Page 97: Checking The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 13 – Insert the new brake linings, insert pin , and mount cotter F02416-11 – 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 98: Adjusting The Free Travel Of The Foot Brake Lever

    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.) – Stand vehicle upright.

  • Page 99: Adding Rear Brake Fluid

    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 100: 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 101 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 102 13 BRAKE SYSTEM – Clean the brake caliper and the brake caliper bracket. – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated correctly. L02780-10 – Insert new brake linings , insert pin , and mount cotter pin.

  • Page 103: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 104: Removing Rear Wheel

    14 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Clean and grease the radial shaft seal rings and the contact surface of the wheel spindle.
  • Page 105 WHEELS, TIRES 14 Main work – Press brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...

  • Page 106: Installing The Rear Wheel

    14 WHEELS, TIRES 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. Main work –...

  • Page 107: Checking Rear Hub Damping Rubber Pieces

    Checking tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 108: Checking Tire 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 H01144-01 years at the latest, regardless of the actual state of wear.

  • Page 109: 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 110: 15 Electrical System

    15 ELECTRICAL SYSTEM 15.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 111: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 Guideline Nut, cable on 12‑V 5 Nm (3.7 lbf ft) battery – Position fuel vapor valve on the holder. A00747-11 Finishing work – Mount the seat. ( p. 67) 15.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. –...

  • Page 112: Changing Main Fuse

    15 ELECTRICAL SYSTEM Main work – Connect a battery charger to the 12-V battery. Switch on the battery charger. Battery charger (79629974000) It is impossible to overcharge the 12-V battery using this device. Info Only charge the 12-V battery with the specified battery M01573-01 charger.

  • Page 113: Changing The Fuses Of Individual Electrical Power Consumers

    ELECTRICAL SYSTEM 15 – Take off protection cap – Remove faulty main fuse A00751-10 – Insert a new main fuse. Fuse (58011109130) ( p. 139) Info Replace a faulty fuse by an equivalent fuse only. A spare fuse is located in the starter relay. –...
  • Page 114 15 ELECTRICAL SYSTEM Main work – Push on locks and take off fuse box cover F02425-10 – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ICO Speedocap, turn signal, instrument Fuse 2 - 10 A - road book Fuse 3 - 5 A - Iritrack Fuse 4 - 5 A - GPS Fuse 5 - 5 A - brake light, coolant temperature indicator...

  • Page 115: Cooling System 16

    COOLING SYSTEM 16 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 . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 116: Checking The Coolant Level

    16 COOLING SYSTEM Coolant ( p. 164) – Mount the radiator cap. 16.3 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 117: Refilling With Coolant

    COOLING SYSTEM 16 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 118: Changing The Coolant

    16 COOLING SYSTEM – Check the coolant level. ( p. 114) 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 119 COOLING SYSTEM 16 Finishing work – Install the engine guard. ( p. 89)

  • Page 120: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – 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 Play in throttle cable 3 …...

  • Page 121: Adjusting The Idle Speed

    TUNING THE ENGINE 17 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 122: Checking Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.4 Checking basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 123: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 18.1 Checking the engine oil level Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 124 18 SERVICE WORK ON THE ENGINE – Remove screw plug with the short oil screen and the O- rings. S03046-10 – Remove screw plug with long oil screen and the O- rings. – Allow the engine oil to drain completely. –...
  • Page 125 SERVICE WORK ON THE ENGINE 18 – Remove screws . Remove the oil filter cover with the O-ring. S03039-10 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. –...
  • Page 126 18 SERVICE WORK ON THE ENGINE – Fill oil filter housing at opening with oil and wait until air bubbles stop rising. Total filling level, oil change Engine oil 1.40 l Engine oil (1.48 qt.) (SAE 10W/50) p. 164) Total filling level, engine service (with oil radiator) Engine oil 1.80 l Engine oil...

  • Page 127: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 18.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove oil filler plug with the O-ring from the clutch cover. –...

  • Page 128: 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 129: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Preserving materials for paints, metal and rubber p.

  • Page 130: 20 Storage

    – 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 a lift stand. ( p. 55) – Cover vehicle with a tarp or similar cover that is permeable to...

  • Page 131: Preparing For Use After Storage

    STORAGE 20 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus- ing engine parts and the exhaust system to rust.

  • Page 132: 21 Troubleshooting

    – Check the electrical system. – Error in the electronic fuel Read out fault memory using the KTM injection diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out fault memory using the KTM injection diagnostics tool.
  • Page 133 See blink code – Check cabling for damage and electri- cal plug-in connections for corrosion and damage. – Read out fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.
  • Page 134 21 TROUBLESHOOTING Faults Possible cause Action – The high beam, low beam, Fuse 6 is blown Change the fuses of individual electri- position light, tail light, license cal power consumers. ( p. 111) plate lamp, and horn are not working...

  • Page 135: Blink Code 22

    BLINK CODE 22 Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x briefly Crankshaft speed sensor – circuit fault Error level condition Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x briefly...
  • Page 136 22 BLINK CODE Blink code FI warning lamp (MIL) 41 FI warning lamp (MIL) flashes 4x long, 1x briefly Error level condition Fuel pump relay - short circuit to ground or open circuit Open/short circuit to plus...

  • Page 137: Technical Data 23

    TECHNICAL DATA 23 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 Idle speed 2,400 ± 200 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 138: Engine Tightening Torques

    23 TECHNICAL DATA 23.2 Engine tightening torques Screw, oil nozzle for piston cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Crankshaft speed sensor screw and 6 Nm (4.4 lbf ft) Loctite ® 243™ cable retainer Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Loctite ®...

  • Page 139: Capacities

    TECHNICAL DATA 23 Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Oil nozzle for conrod bearing lubri- M6x0.75 2 Nm (1.5 lbf ft) cation Plug, oil channel 9 Nm (6.6 lbf ft) Loctite ®...

  • Page 140: Fuel

    23 TECHNICAL DATA 23.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Front left fuel tank, approx. Super unleaded (ROZ 95) ( p. 165) 8.0 l (2.11 US gal) Front right fuel tank, approx. Super unleaded (ROZ 95) ( p.

  • Page 141: Electrical System

    140/80 - 18 M/C 70R M+S TT Continental TKC 80 Continental TKC 80 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork article number 14.18.2S.40...

  • Page 142: Shock Absorber

    23 TECHNICAL DATA Fork length 950 mm (37.4 in) Oil capacity fork leg without car- 445 ml (15.05 fl. oz.) Fork oil (SAE 4) (48601166S1) tridge p. 165) Oil capacity per cartridge 165 ml (5.58 fl. oz.) Fork oil (SAE 4) (48601166S1) p.

  • Page 143: Chassis Tightening Torques

    TECHNICAL DATA 23 23.9 Chassis tightening torques Screw, combination instrument EJOT PT K45x12 2 Nm (1.5 lbf ft) Screw, license plate holder, bot- EJOT 3 Nm (2.2 lbf ft) Screw, license plate lamp EJOT PT K50x18 T20 1.5 Nm (1.11 lbf ft) Screw, tail light EJOT PT K60x20 5 Nm (3.7 lbf ft)
  • Page 144 23 TECHNICAL DATA Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp 17 Nm (12.5 lbf ft) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, connection lever on frame 30 Nm (22.1 lbf ft) Loctite ®...
  • Page 145 TECHNICAL DATA 23...

  • Page 146: 24 Wiring Diagram

    24 WIRING DIAGRAM 24.1 Page 1 of 10 A00759-01...
  • Page 147 WIRING DIAGRAM 24 Components: Electric starter system Starter relay with main fuse 12-V battery Capacitor Voltage regulator Alternator Power relay...

  • Page 148: 146

    24 WIRING DIAGRAM 24.2 Page 2 of 10 A00760-01...
  • Page 149 WIRING DIAGRAM 24 Components: Fuse Diode Radiator fan Temperature switch Fuse Diode High beam relay Low beam relay...

  • Page 150: 148

    24 WIRING DIAGRAM 24.3 Page 3 of 10 A00761-01...
  • Page 151 WIRING DIAGRAM 24 Components: Fuse Relay for rear fuel pump Rear fuel pump Relay for front fuel pump Front fuel pump...

  • Page 152: 150

    24 WIRING DIAGRAM 24.4 Page 4 of 10 A00762-01...
  • Page 153 WIRING DIAGRAM 24 Components: EFI control unit CAN bus terminating resistor Injection valve Fuel vapor valve Lambda sensor...

  • Page 154: 152

    24 WIRING DIAGRAM 24.5 Page 5 of 10 A00763-01...
  • Page 155 WIRING DIAGRAM 24 Components: EFI control unit Coolant temperature sensor Ignition coil Crankshaft speed sensor Shift shaft sensor Throttle valve position sensor Tilt sensor Induction manifold pressure sensor Intake air temperature sensor...

  • Page 156: 154

    24 WIRING DIAGRAM 24.6 Page 6 of 10 A00764-01...
  • Page 157 WIRING DIAGRAM 24 Components: Fuse Fuse Fuse Fuse Fuse Rear brake light switch Brake/tail light Oil pressure sensor...

  • Page 158: 156

    24 WIRING DIAGRAM 24.7 Page 7 of 10 A00765-01...
  • Page 159 WIRING DIAGRAM 24 Components: Rear fuel level warning lamp Front fuel level warning lamp Fuel pump switch Electric starter button Malfunction indicator lamp...

  • Page 160: 158

    24 WIRING DIAGRAM 24.8 Page 8 of 10 A00766-01...
  • Page 161 WIRING DIAGRAM 24 Components: Indicator lamp for coolant temperature Oil pressure warning lamp Crankshaft speed sensor Induction manifold pressure sensor Light switch, horn button, stop button Low beam High beam Position light...

  • Page 162: 160

    24 WIRING DIAGRAM 24.9 Page 9 of 10 A00767-01...
  • Page 163 WIRING DIAGRAM 24 Components: Horn...

  • Page 164: 162

    24 WIRING DIAGRAM 24.10 Page 10 of 10 A00768-01...
  • Page 165 WIRING DIAGRAM 24 Turn signal relay Turn signal switch Turn signal indicator lamp Right front turn signal Left front turn signal Right rear turn signal Left rear turn signal License plate lamp Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet...

  • Page 166: 25 Substances

    25 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 167 SUBSTANCES 25 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 168) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 168: 26 Auxiliary Substances

    ® – Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier MOTOREX ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE Silicone spray Recommended supplier MOTOREX ® – Silicone Spray...
  • Page 169 AUXILIARY SUBSTANCES 26 Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 170: 27 Standards

    27 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 171: Index Of Special Terms 28

    INDEX OF SPECIAL TERMS 28 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 172: 29 List Of Abbreviations

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

  • Page 173: List Of Symbols 30

    Left fuel level warning lamp lights up orange – The fuel level of the two front fuel tanks has reached the reserve mark. Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. 30.3 Green and blue symbols Green and blue symbols reflect information.
  • Page 174 INDEX Cleaning ......126-127 INDEX Clutch 12-V battery fluid level, checking/correcting ... 83 charging .
  • Page 175 INDEX dust boots, cleaning ....56 installing ......58 Light switch .
  • Page 176 INDEX shock absorber, adjusting ....47 chassis ......138 chassis tightening torques .
  • Page 177 *3214230en* 3214230en 09/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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