KTM 890 DUKE 2021 Owner's Manual
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KTM 890 DUKE 2021 Owner's Manual

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OWNER'S MANUAL
2021
890 DUKE
Art. no. 3214300en

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Summary of Contents for KTM 890 DUKE 2021

  • Page 1 OWNER'S MANUAL 2021 890 DUKE Art. no. 3214300en...
  • 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 Switches on the right side of the TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 handlebar........17 Symbols used ........5 6.5.1 Start button/emergency OFF Formats used........5 switch......... 17 Ignition and steering lock....18 SAFETY ADVICE..........6 Opening fuel tank filler cap....
  • Page 5 Removing the rear of the motorcycle 7.16.31 Shift Light ........40 from the lifting gear ......64 7.16.32 KTM MY RIDE (optional) ....41 13.3 Lifting the motorcycle with the front lifting gear ........64 7.16.33 Pairing (optional) ......41 13.4...
  • Page 6 TABLE OF CONTENTS 16.6 Changing the ABS fuses ....94 23 TECHNICAL DATA........119 16.7 Changing the fuses of individual 23.1 Engine .......... 119 electrical power consumers ....95 23.2 Engine tightening torques ....120 16.8 Loosening the headlight mask with 23.3 Capacities ........

  • Page 7: Means Of Representation 1

    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 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on race courses. This vehicle is not suitable for offroad use. 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 9: Tampering Warning

    An appropriate driver's license is needed to drive the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    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 11: Important Notes 3

    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 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00920-10 Combination instrument ( p. 22) Ignition and steering lock ( p. 18) Clutch lever ( p. 14) Seat lock ( p. 19) Side stand ( p. 21) Shift lever ( p.

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) A00921-10 Tool set ( p. 19) Fuel tank filler cap Light switch ( p. 15) Turn signal switch ( p. 17) Horn button ( p. 17) Start button/emergency OFF switch ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 402324-10 Type label The type label is located on the steering head on the left. The type label Australia is located on the frame behind the steering head at the top left.

  • Page 15: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the inner side of the fork stub. 402295-10 Shock absorber article number Shock absorber article number is on the left side of the shock absorber. V01201-10 Steering damper article number Steering damper article number is embossed on the underside of the steering damper.

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. V01187-10 Hand brake lever The hand brake lever is located on the right side of the han- dlebar. The front brake is engaged using the hand brake lever. V01188-10 Throttle grip The throttle grip...

  • Page 17: Light Switch

    CONTROLS 6 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch in position . In this position, the low beam and the tail light are switched High beam on – Push the light switch to position In this position, the high beam and the tail light are switched on.

  • Page 18: Menu Buttons

    6 CONTROLS – Operating the hand brake lever – Operating the foot brake lever – Operating the clutch lever – Shifting gears – Turning the throttle grip beyond the basic position – Control of the motorcycle traction control (MTC) – Slip at the rear wheel or lifting front wheel –...

  • Page 19: Turn Signal Switch

    CONTROLS 6 6.4.5 Turn signal switch The turn signal switch is fitted on the left side of the handle- bar. Possible states Turn signal off Left turn signal on – Turn signal switch pressed to the left. The turn signal switch returns to the center position after activation.

  • Page 20: Ignition And Steering Lock

    6 CONTROLS Ignition and steering lock The ignition and steering lock is located in front of the upper triple clamp. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

  • Page 21: Closing The Fuel Tank Filler Cap

    CONTROLS 6 – Lift the fuel tank filler cap. Closing the fuel tank filler cap – Fold down the fuel tank filler cap. – Turn the ignition key 90° clockwise. – Push down the fuel tank filler cap and turn the ignition key counterclockwise until the lock closes.

  • Page 22: Grab Handle

    6 CONTROLS 6.11 Grab handle The grab handle is used for maneuvering the motorcycle. If you carry a passenger, the passenger can hold onto the grab handles during the trip. V01225-10 6.12 Passenger foot pegs The passenger foot pegs can be folded up and down. Possible states Passenger foot pegs folded up –...

  • Page 23: Foot Brake Lever

    CONTROLS 6 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 402177-10 6.15 Side stand The side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle.

  • Page 24: Combination Instrument

    (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop. The oil pressure warning lamp always lights up as long as the engine is not running. If the engine is running and the...

  • Page 25: Warnings

    COMBINATION INSTRUMENT 7 Night mode is shown in a dark color. Info The ambient light sensor in the combination instrument measures the brightness of the environment and automat- ically switches the display to day or night mode. The dis- play is brightened, darkened or switched to the other mode depending on the brightness measured by the ambient light sensor.
  • Page 26 107) is not enabled or is currently interven- ing. The TC indicator lamp also lights up if a malfunction is detected. Contact an authorized KTM workshop. The TC indicator lamp flashes if MTC actively engages or if the Launch Control p. 52) is activated.

  • Page 27: Display

    COMBINATION INSTRUMENT 7 Display F02747-10 Info The figure shows the start screen of the combination instrument. If the menu is opened, the speed is still displayed. Gear display Heated grip (optional) ( p. 26) Cruise control indicator (optional) ( p. 27) Bluetooth ®...

  • Page 28: Track Display

    7 COMBINATION INSTRUMENT TRACK display F02748-10 Info The figure shows the start screen of the combination instrument in active drive mode TRACK. If the menu is opened, the speed is still displayed. Throttle response (optional) ( p. 108) Slip adjustment (optional) ( p.

  • Page 29: Cruise Control Indicator (Optional)

    COMBINATION INSTRUMENT 7 Cruise control indicator (optional) When cruise control (optional) is activated, the operating mode is shown on the combination instrument display. Cruise control is operated using the cruise control tip switch p. 15). F02755-10 7.10 Fuel level display The fuel level indicator consists of bars.

  • Page 30: Trip Odometer

    7 COMBINATION INSTRUMENT Engine hot – Six to eight bars light up. • Engine very hot – All eight bars flash orange. • 7.12 Trip odometer Trip 1 is displayed in the start screen as a trip odometer. This can- not be changed.

  • Page 31: Menu

    COMBINATION INSTRUMENT 7 The shift warning 6,500 rpm light always lights up 7.16 Menu Info Press the SET button to open the menu. Navigate through the menu using the UP button the DOWN button Press the BACK button to close the current menu or the menu overview.

  • Page 32: Trip 2

    7 COMBINATION INSTRUMENT 7.16.3 Trip 2 – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 33: Settings

    7.16.6 Condition • The motorcycle is stationary. • Function KTM MY RIDE (optional) activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu.

  • Page 34: Temperature

    7 COMBINATION INSTRUMENT 7.16.8 Temperature Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 35: Language

    COMBINATION INSTRUMENT 7 7.16.11 Language Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 36: Tpms Warning

    7 COMBINATION INSTRUMENT Warning Danger of accidents When visibility is poor, the day- time running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain.

  • Page 37: Quick Selector 1

    COMBINATION INSTRUMENT 7 7.16.15 Quick Selector 1 Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 38: Set Favorites

    7 COMBINATION INSTRUMENT 7.16.17 Set Favorites Condition • The motorcycle is stationary. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Trips/Data menu is marked on the display. Press the SET button to open the menu. –...

  • Page 39: Extra Functions

    V01126-01 tions. Info The optional extra functions are listed in Extra functions. The current KTM PowerParts and the available software for your vehicle can be found on the KTM website. 7.16.21 Warnings Condition • At least one warning present. –...

  • Page 40: Track (Optional)

    7 COMBINATION INSTRUMENT Info Do not open the throttle during the selection. 7.16.23 Track (optional) Condition • The TRACK riding mode (optional) is activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Ride Mode menu is marked on the display.

  • Page 41: Heated Grips (Optional)

    COMBINATION INSTRUMENT 7 7.16.26 Heated Grips (optional) Condition • The Heated Grips menu activated. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Motorcycle menu is marked on the display. Press the SET button to open the menu. –...

  • Page 42: Abs Mode

    7 COMBINATION INSTRUMENT 7.16.29 ABS Mode Condition • The motorcycle is stationary. • ABS is switched on. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the Motorcycle menu is marked on the display. Press the SET button to open the menu. –...

  • Page 43: Ktm My Ride (Optional)

    Press the SET button when the menu is closed. – Press the UP or DOWN button until the KTM MY RIDE menu is marked on the display. Press the SET button to open the menu. In KTM MY RIDE, an appropriate cellphone or headset can be paired via Bluetooth ®...

  • Page 44: Audio Player (Optional)

    Headset connected to a suitable audio device. – Press the SET button when the menu is closed. – Press the UP or DOWN button until the KTM MY RIDE menu is marked on the display. Press the SET button to open the menu. H02860-01 Warning Danger of accidents Headphone volume which is too...

  • Page 45: Telephony (Optional)

    The audio function can be added to Quick Selector 1 or Quick Selector 2 for easier operation. 7.16.35 Telephony (optional) Condition • Function KTM MY RIDE (optional) activated. Bluetooth ® • (optional) switched on. •...

  • Page 46: Ergonomics

    Info V01210-11 KTM recommends the front handlebar position when using the vehicle on a race track. Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk.

  • Page 47: Adjusting The Basic Position Of The Clutch Lever

    ERGONOMICS 8 Adjusting the basic position of the clutch lever – Push the clutch lever forward. – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 48: Checking The Basic Position Of The Shift Lever

    8 ERGONOMICS – Detach spring – Loosen nut Press the foot brake lever downwards to make this eas- ier. – Turn the push rod to set the basic position of the foot brake lever. V01229-10 Info The range of adjustment is limited. The screw must be screwed in by at least five full turns.

  • Page 49: Adjusting The Basic Position Of The Shift Lever

    ERGONOMICS 8 – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the gear shift lever. Distance between shift lever 10 … 20 mm (0.39 … and upper edge of boot 0.79 in) »...

  • Page 50: Preparing For Use

    When using your vehicle, 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 51: Running In The Engine

    PREPARING FOR USE 9 – Run the engine in. ( p. 49) Running in the engine – During the running-in phase, do not exceed the specified engine speed. Guideline Maximum engine speed During the first: 1,000 km (620 mi) 6,500 rpm After the first: 1,000 km (620 mi) 9,800 rpm –...
  • Page 52 9 PREPARING FOR USE Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system. – If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

  • Page 53: Riding Instructions 10

    RIDING INSTRUCTIONS 10 10.1 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 54: Starting Off

    10 RIDING INSTRUCTIONS – Press the start button/emergency OFF switch into the lower position Info Only press the start button/emergency OFF switch into the lower position when the combination instrument function check has been completed. Do not open the throttle to start. Press the start button/emergency OFF switch into the lower position for a maximum of five seconds.

  • Page 55: Quickshifter + (Optional)

    RIDING INSTRUCTIONS 10 Condition The TRACK riding mode (optional) is activated. First gear is engaged. The TC indicator lamp does not light up. Coolant temperature: > 60 °C (> 140 °F) Total riding distance covered: > 1,000 km (> 620 mi) –...
  • Page 56 10 RIDING INSTRUCTIONS Warning Danger of accidents An incorrect ignition key position causes malfunctions. – Do not change the ignition key position while driving. Warning Danger of accidents Adjustments to the vehicle distract attention from traffic activity. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly.
  • Page 57 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. – Shift into a higher gear when conditions allow (incline, road situation, etc.).

  • Page 58: Engine Traction Torque Control (Msr)

    10 RIDING INSTRUCTIONS – If the general warning lamp lights up during a trip, the dis- play shows a message. Info Very important messages are stored in the Warnings menu. – If the ice warning appears in the combination instrument, the roads may be icy.

  • Page 59: 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 60: Stopping, Parking

    10 RIDING INSTRUCTIONS – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over rev the engine. As a result, you will have to apply the brakes far less frequently and the brake system will not overheat.

  • Page 61: Transporting

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 62 10 RIDING INSTRUCTIONS Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open fuel tank filler cap. ( p.

  • Page 63: Service Schedule 11

    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 64: Recommended Work

    ● ● ● Set the service interval display. ○ ● ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ● Periodic interval 11.3 Recommended work every 48 months every 12 months every 30,000 km (18,600 mi)

  • Page 65: Tuning The Chassis 12

    TUNING THE CHASSIS 12 12.1 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 66: Service Work On The Chassis

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

  • Page 67: Taking The Motorcycle Off The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 13 13.4 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. – Secure the motorcycle against falling over. –...

  • Page 68: Removing The Passenger Seat

    13 SERVICE WORK ON THE CHASSIS 13.6 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the passenger seat cover, push it toward the rear, and remove it upward. –...

  • Page 69: Mounting The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 13 13.9 Mounting the front rider's seat Main work – Push the front rider's seat forward and lower at the rear. The holding lugs engage in the loops on the tank. The holding lugs engage in the loops on the frame.

  • Page 70: Cleaning The Chain

    13 SERVICE WORK ON THE CHASSIS 13.11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 71: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 13 Main work – Shift the transmission to neutral position. – Push the chain behind the chain sliding piece up and deter- mine the chain tension between the swingarm and the upper edge of the chain. Guideline 2.5 cm (0.98 in) Distance...

  • Page 72: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    13 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 2 … 5 mm (0.08 … 0.2 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in...
  • Page 73 SERVICE WORK ON THE CHASSIS 13 – Shift the transmission to neutral position. – Pull on the lower chain section with the specified weight Guideline Weight of chain wear mea- 15 kg (33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 74 13 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If continuous signs of wear to the chain are visible on the chain sliding guard in the area marked: – Replace the chain sliding guard. »...

  • Page 75: Brake System 14

    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 the specified tire pressure. –...

  • Page 76: Checking The Brake Discs

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

  • Page 77: Adding Front 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 78: 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 79: 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.) – Stand the vehicle upright.
  • Page 80 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 81: 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 82: Wheels, Tires

    15 WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 64) – Lift the motorcycle with the front lifting gear. ( p. 64) Main work – Remove screw and pull wheel speed sensor out of the hole.

  • Page 83: Installing The Front Wheel

    WHEELS, TIRES 15 15.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 84: Removing The Rear Wheel

    15 WHEELS, TIRES – Position both brake calipers. The brake linings are correctly positioned. – Mount screws on both sides but do not tighten yet. Guideline Screw, front M10x1.25 45 Nm (33.2 lbf ft) Loctite ® 243™ brake caliper – 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 85: Installing The Rear Wheel

    WHEELS, TIRES 15 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. – Remove screw and pull wheel speed sensor out of the hole. – Remove nut . Take off chain adjuster –...
  • Page 86 15 WHEELS, TIRES Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel. – Actuate the foot brake several times before going on a ride until you can feel a firm pressure point. Main work –...

  • Page 87: Checking The Rear Hub Damping Rubber Pieces

    WHEELS, TIRES 15 Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. Finishing work –...

  • Page 88: 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 89: 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 years at the latest, regardless of the actual state of H01144-10 wear.
  • Page 90 15 WHEELS, TIRES We recommend transporting the broken down vehicle to the near- est workshop instead of using tire repair spray. (Option: With TPMS) Note Material damage Tire repair spray damages the tire pressure sensor. – Note that after using tire repair spray, the tire pressure sensor may need to be replaced.

  • Page 91: Electrical System 16

    ELECTRICAL SYSTEM 16 16.1 Daytime running light (DRL) Warning Danger of accidents When visibility is poor, the daytime running light is not a substitute for the low beam. Automatic switching between the daytime running light and low beam may only be partially available when visi- bility is significantly impaired due to fog, snow or rain.

  • Page 92: Installing The 12-V Battery

    16 ELECTRICAL SYSTEM Main work – Disconnect negative cable from the 12-V battery. – Remove positive terminal cover V01203-11 – Disconnect positive cable from the 12-V battery. – Take negative cable out of holders on the battery support bracket. – Remove screw –...

  • Page 93: Charging The 12-V Battery

    ELECTRICAL SYSTEM 16 – Hook negative cable into the holders on the battery support bracket. – Mount positive terminal cover – Connect negative cable to the 12 V battery. Guideline Screw, battery termi- M6x12 4.5 Nm (3.32 lbf ft) V01203-10 Finishing work –...
  • Page 94 16 ELECTRICAL SYSTEM Preparatory work – Remove the passenger seat. ( p. 66) Main work – Disconnect negative cable from the 12 V battery to avoid damaging the onboard electronics. – Remove positive terminal cover V01203-11 – Connect a battery charger to the 12-V battery. Switch on the battery charger.

  • Page 95: Changing The Main Fuse

    ELECTRICAL SYSTEM 16 16.5 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all electrical power consumers of the vehicle. The main fuse is under the passen- ger seat.

  • Page 96: Changing The Abs Fuses

    16 ELECTRICAL SYSTEM 16.6 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS.

  • Page 97: Changing The Fuses Of Individual Electrical Power Consumers

    ELECTRICAL SYSTEM 16 16.7 Changing the fuses of individual electrical power consumers Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The fuse box containing the fuses of individual electrical power consumers is located under the seat. Preparatory work –...

  • Page 98: Loosening The Headlight Mask With The Headlight

    16 ELECTRICAL SYSTEM Put a spare fuse in the fuse box so that it is available if needed. – Check the function of the electrical power consumer. – Close the fuse box cover. Finishing work – Mount the passenger seat. ( p.

  • Page 99: Removing The Cover Of The Headlight Mask Rack

    ELECTRICAL SYSTEM 16 – Mount adjusting screw V01212-11 Finishing work – Check the headlight setting. ( p. 98) 16.10 Removing the cover of the headlight mask rack Info The cover of the headlight mask rack must be removed in order to gain access to the ACC1 and ACC2 power supply.

  • Page 100: Installing The Cover Of The Headlight Mask Rack

    16 ELECTRICAL SYSTEM 16.11 Installing the cover of the headlight mask rack Main work – Position cover by guiding the plug-in connector of the head- light through the opening. – Hold turn signal in the area and carefully press against the direction of travel, while pressing the cover tight at the same time.

  • Page 101: Adjusting The Headlight Range

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

  • Page 102: Front Acc1 And Acc2

    16 ELECTRICAL SYSTEM 16.15 Front ACC1 and ACC2 Installation location – Power supplies ACC1 and ACC2 front are located under the cover of the headlight mask rack. V01216-10 16.16 ACC1 and ACC2 rear Installation location – The rear power supplies ACC1 and ACC2 are located under the passenger seat next to the battery compartment.

  • Page 103: Cooling System 17

    COOLING SYSTEM 17 17.1 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 104: Checking The Coolant Level In The Compensating Tank

    17 COOLING SYSTEM Main work – Remove radiator cap and cap of the compensating tank. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … Antifreeze −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: A00956-10 –...

  • Page 105: Draining The Coolant

    COOLING SYSTEM 17 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 106: Filling/Bleeding The Cooling System

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

  • Page 107: Changing The Coolant

    COOLING SYSTEM 17 – Remove bleeder screw – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw immedi- ately. Coolant 1.6 l (1.7 qt.) Coolant ( p.
  • Page 108 17 COOLING SYSTEM – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw with the seal ring. V01254-11 – Remove radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw plug, EJOTALtracs...

  • Page 109: Tuning The Engine 18

    TUNING THE ENGINE 18 18.1 Ride Mode Possible states SPORT – Homologated performance with very direct response; • the motorcycle traction control allows greater slip on the rear wheel. STREET – Homologated performance with balanced response; • the motorcycle traction control allows normal slip on the rear wheel.

  • Page 110: Slip Adjustment (Optional)

    18 TUNING THE ENGINE 18.3 Slip adjustment (optional) The spin adjuster is a motorcycle traction control function. The slip adjustment allows the motorcycle traction control to be tuned through nine levels to the desired characteristic map. Level 1 allows the maximum slip on the rear wheel, and level 9 the minimum.

  • Page 111: Service Work On The Engine 19

    SERVICE WORK ON THE ENGINE 19 19.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 112 19 SERVICE WORK ON THE ENGINE – Remove oil drain plugs along with the magnets, the O- rings, and the oil screens. V01235-10 – Remove screws . Take off oil filter cover with the O- ring. – Pull oil filter out of the oil filter housing.

  • Page 113: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 19 – Mount and tighten filler plug with the O-ring. 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.

  • Page 114: Checking The Free Travel Of The Clutch Lever

    19 SERVICE WORK ON THE ENGINE 19.4 Checking the free travel of the clutch lever Note Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip. – Check the free travel of the clutch lever each time before using the motorcycle. –...

  • Page 115: Cleaning, Care 20

    CLEANING, CARE 20 20.1 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 116: Checks And Maintenance Steps For Winter Operation

    20 CLEANING, CARE – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 68) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 117: Storage 21

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 64) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 118: Preparing For Use After Storage

    21 STORAGE 21.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 65) – Remove the rear of the motorcycle from the lifting gear. p. 64) – Charge the 12-V battery. p. 91) –...

  • Page 119: Troubleshooting 22

    Join quick release coupling. joined – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Throttle opened while starting When starting, DO NOT open the throt- tle. – Carry out start procedure. ( p.
  • Page 120 – Malfunction in ABS Read out the ABS 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 121: Technical Data 23

    TECHNICAL DATA 23 23.1 Engine Design 2-cylinder 4-stroke in-line engine, water-cooled Displacement 890 cm³ (54.31 cu in) Stroke 68.8 mm (2.709 in) Bore 90.7 mm (3.571 in) Compression ratio 13.5:1 Control DOHC, 4 valves per cylinder controlled via cam lever, chain drive Valve diameter, intake 37 mm (1.46 in)

  • Page 122: Engine Tightening Torques

    23 TECHNICAL DATA 23.2 Engine tightening torques EJOTALtracs Plus 60x14 Screw plug, water pump drain hole ® 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, bleeder flange EJOTALtracs ® M6x12 8 Nm (5.9 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Nozzle, engine vent 2 Nm (1.5 lbf ft)
  • Page 123 TECHNICAL DATA 23 Screw, locking lever 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, main shaft bearing support 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil pan M6x30 10 Nm (7.4 lbf ft) Screw, oil pan M6x35 10 Nm (7.4 lbf ft) Screw, oil pump cover 10 Nm (7.4 lbf ft)

  • Page 124: Capacities

    23 TECHNICAL DATA Screw, conrod bearing M8x0.75 1st stage 5 Nm (3.7 lbf ft) 2nd stage 20 Nm (14.8 lbf ft) 3rd stage 90° Screw support and thread oiled Spark plug 11 Nm (8.1 lbf ft) Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) Screw plug, bearing support M10x1...

  • Page 125: Fuel

    TECHNICAL DATA 23 23.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Fuel tank capacity, approx. 14 l (3.7 US gal) Super unleaded (ROZ 95) p. 131) 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tub- ing, powder-coated WP APEX 3043 Fork...

  • Page 126: Electrical System

    120/70 ZR 17 M/C (58W) TL (J) 180/55 ZR 17 M/C (73W) TL (G) Continental ContiRoad Continental ContiRoad 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 0636C126U201102 Fork...

  • Page 127: Chassis Tightening Torques

    TECHNICAL DATA 23 Medium (standard) 140 … 185 N/mm (799 … 1,056 lb/in) Gas pressure 16 bar (232 psi) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 131) 23.9 Chassis tightening torques Radiator hose hose clamp 2.2 Nm (1.62 lbf ft) Remaining screws, chassis EJOTPT ®...
  • Page 128 23 TECHNICAL DATA Nut, shift rod 6 Nm (4.4 lbf ft) Nut, shift rod M6LH 6 Nm (4.4 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, activated carbon filter 6 Nm (4.4 lbf ft) holder Screw, angle sensor...
  • Page 129 TECHNICAL DATA 23 Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ Pin, rear brake caliper 22 Nm (16.2 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp 12 Nm (8.9 lbf ft) Screw, cross member...
  • Page 130 23 TECHNICAL DATA Screw, subframe brace 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, top triple clamp 15 Nm (11.1 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Loctite ® 243™ Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, front footrest bracket...

  • Page 131: Declarations Of Conformity 24

    Declaration of Conformity is available at the following Internet address. Certification website: http://www.ktm.com/btrouter KTM AG hereby declares that the Immo641 wireless system conforms with the relevant guidelines. The full text of the Declaration of Conformity is available at the following Internet address.

  • Page 132: 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 133 SUBSTANCES 25 Fork oil (SAE 5) Standard/classification – SAE ( p. 133) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Recommended supplier MOTOREX ® –...

  • Page 134: Auxiliary Substances

    26 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 135: Standards 27

    STANDARDS 27 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 136: Index Of Special Terms

    Auxiliary function of the engine control, which pre- vents rear wheel locking with excessive engine braking effect, by lightly opening the throttle valve KTM MY RIDE System for wireless communication with appropriate cellphones and headsets for telephony and audio Launch control...

  • Page 137: List Of Abbreviations 29

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

  • Page 138: List Of Symbols

    107) is not enabled or is currently interven- ing. The TC indicator lamp also lights up if a malfunction is detected. Contact an authorized KTM workshop. The TC indicator lamp flashes if MTC actively engages or if the Launch Control p. 52) is activated.

  • Page 139: Index

    ..... 23 KTM MY RIDE ..... . . 41 Brake discs Language .
  • Page 140 INDEX warnings ..... . . 23, 37 Front rider's seat removing ......66 Combination switch .
  • Page 141 INDEX raising with the rear lifting gear ..64 Shifting ......53 rear from the lifting gear, removing .
  • Page 142 INDEX Work rules ......8...
  • Page 143 *3214300en* 3214300en 02/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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