KTM 790 DUKE 2021 Owner's Manual
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KTM 790 DUKE 2021 Owner's Manual

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OWNER'S MANUAL
2021
790 DUKE
Art. no. 3214299en

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Summary of Contents for KTM 790 DUKE 2021

  • Page 1 OWNER'S MANUAL 2021 790 DUKE Art. no. 3214299en...
  • 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 Ignition and steering lock....16 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Opening fuel tank filler cap....16 Symbols used ........5 Closing the fuel tank filler cap... 17 Formats used........5 Seat lock......... 18 SAFETY ADVICE..........6 6.10 Tool set...........
  • Page 5 TABLE OF CONTENTS 7.13.30 KTM MY RIDE (optional) ....37 13.4 Taking the motorcycle off the front lifting gear ........62 7.13.31 Pairing (optional) ......38 13.5 Cleaning the dust boots of the fork 7.13.32 Audio player (optional) ....39 legs ..........
  • Page 6 TABLE OF CONTENTS 16.12 Checking the headlight setting ..95 23.9 Chassis tightening torques ....122 16.13 Adjusting the headlight range.... 96 24 DECLARATIONS OF CONFORMITY ..... 126 16.14 Diagnostics connector ...... 96 24.1 Declarations of conformity ....126 16.15 Front ACC1 and ACC2 ...... 97 24.2 Country-specific declarations of 16.16 ACC1 and ACC2 rear ......

  • 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) V01494-10 Combination instrument ( p. 20) Ignition and steering lock ( p. 16) Clutch lever ( p. 14) Passenger seat Grab handle ( p. 18) Seat lock ( p. 18) Side stand ( p.

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) V01493-10 Tool set ( p. 18) Fuel tank filler cap Light switch ( p. 15) Turn signal switch ( p. 15) Horn button ( p. 15) 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: Switches On The Right Side Of The Handlebar

    6 CONTROLS Switches on the right side of the handlebar 6.5.1 Start button/emergency OFF switch The start button/emergency OFF switch is fitted on the right side of the combination switch. Possible states Start button/emergency OFF switch off (upper posi- tion) – In this position, the ignition circuit is inter- rupted, a running engine stops, and a non-running engine cannot be started.

  • Page 19: Closing The Fuel Tank Filler Cap

    CONTROLS 6 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 20: Seat Lock

    6 CONTROLS Seat lock The seat lock is located on the left side of the vehicle. It can be locked with the ignition key. V01198-10 6.10 Tool set The tool set is located under the passenger seat. V01214-10 6.11 Grab handle The grab handle is used for maneuvering the motorcycle.

  • Page 21: Shift Lever

    CONTROLS 6 6.13 Shift lever The shift lever is mounted on the left side of the engine. V01271-11 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. V01271-10 6.14 Foot brake lever Foot brake lever...

  • Page 22: 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 23: 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 24 104) 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. 49) is activated.

  • Page 25: Display

    COMBINATION INSTRUMENT 7 Display H02854-10 Info The figure shows the start screen of the combination instrument. If the menu is opened, the speed is still displayed. Gear display Bluetooth ® (optional) Ride Mode ( p. 104) Unit for the speedometer Fuel level display ( p.

  • Page 26: Track Display

    7 COMBINATION INSTRUMENT TRACK display V01299-10 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 ( p. 105) Slip adjustment ( p.

  • Page 27: Fuel Level Display

    COMBINATION INSTRUMENT 7 Fuel level display The fuel level indicator consists of bars. The more bars are lit, the more fuel is in the fuel tank. Info If the fuel level is getting low, the last bar flashes orange and the LOW FUEL warning also appears. The fuel level is displayed with a slight delay to prevent the indicator from constantly moving while riding.

  • Page 28: Odometer

    7 COMBINATION INSTRUMENT Engine hot – Six to eight bars light up. • Engine very hot – All eight bars flash orange. • 7.12 Odometer Trip 1 is displayed in the start screen as an odometer. This cannot be changed. Information about the total riding distance covered can be accessed in the General Info menu under menu item Odometer.

  • Page 29: Trip 2

    COMBINATION INSTRUMENT 7 Fuel range indicates the possible distance you can cover with the fuel reserve. Press and In the Trip 1 menu all entries apart from hold the but- Fuel range are deleted. for 3–5 seconds. 7.13.3 Trip 2 –...

  • Page 30: Settings

    7.13.6 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 31: Temperature

    COMBINATION INSTRUMENT 7 7.13.8 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 32: Language

    7 COMBINATION INSTRUMENT 7.13.11 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 33: Tpms Warning

    COMBINATION INSTRUMENT 7 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 34: Quick Selector 1

    7 COMBINATION INSTRUMENT 7.13.15 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 35: Set Favorites

    Use the UP or DOWN button to navigate through the extra func- 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.

  • Page 36: Warnings

    7 COMBINATION INSTRUMENT 7.13.20 Warnings Condition • At least one warning present. – 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 37: Anti-Wheelie Mode

    COMBINATION INSTRUMENT 7 Info Do not open the throttle when setting it. The drive mode TRACK is ended via Leave Track and automatically switches to the drive mode STREET. Do not open the throttle when doing so. 7.13.23 Anti‑wheelie mode Condition •...

  • Page 38: Abs

    7 COMBINATION INSTRUMENT 7.13.26 ABS Condition • The motorcycle is stationary. Note Voiding of the government approval for road use and the insurance coverage If the ABS is switched off completely, the vehicle's approval for road use is invalidated. – Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off completely.

  • Page 39: Quickshifter

    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 40: Pairing (Optional)

    Press the SET button when the menu is closed. V01137-01 – 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. – Press the UP or DOWN button until Setup is marked on the dis- play.

  • Page 41: 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 42: Telephony (Optional)

    7 COMBINATION INSTRUMENT 7.13.33 Telephony (optional) Condition • Function KTM MY RIDE (optional) activated. • Bluetooth ® (optional) switched on. • Similarly, the Bluetooth ® function is also switched on when devices are paired. • Headset linked with appropriate cellphone.

  • Page 43: Ergonomics 8

    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 44: Adjusting The Basic Position Of The Clutch Lever

    8 ERGONOMICS 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 45: Checking The Basic Position Of The Shift Lever

    ERGONOMICS 8 – 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 46: Adjusting The Basic Position Of The Shift Lever

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

  • Page 47: Preparing For Use 9

    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 48: Running In The Engine

    9 PREPARING FOR USE – Run the engine in. ( p. 46) 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 49 PREPARING FOR USE 9 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 50: Riding Instructions

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

  • Page 51: Starting Off

    RIDING INSTRUCTIONS 10 – 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 52: Quickshifter

    10 RIDING INSTRUCTIONS Condition The drive mode TRACK 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 53 RIDING INSTRUCTIONS 10 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 54 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 55: Engine Traction Torque Control (Msr)

    RIDING INSTRUCTIONS 10 – 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 56: 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 57: Stopping, Parking

    RIDING INSTRUCTIONS 10 – 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 58: 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 59 RIDING INSTRUCTIONS 10 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 60: 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 61: 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 62: Tuning The Chassis

    12 TUNING THE CHASSIS 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 63: Service Work On The Chassis 13

    SERVICE WORK ON THE CHASSIS 13 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 64: Taking The Motorcycle Off The Front Lifting Gear

    13 SERVICE WORK ON THE CHASSIS 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 65: Removing The Passenger Seat

    SERVICE WORK ON THE CHASSIS 13 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 66: Mounting The Front Rider's Seat

    13 SERVICE WORK ON THE CHASSIS 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 67: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 13 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 68: Adjusting The Chain Tension

    13 SERVICE WORK ON THE CHASSIS 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 69: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 13 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 70 13 SERVICE WORK ON THE CHASSIS – 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 71 SERVICE WORK ON THE CHASSIS 13 – 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 72: Brake System

    Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire pressure. –...

  • Page 73: 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 74: 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 75: 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 76: 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 77 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 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 79: Wheels, Tires 15

    WHEELS, TIRES 15 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 61) – Lift the motorcycle with the front lifting gear. ( p. 61) Main work – Remove screw and pull wheel speed sensor out of the hole.

  • Page 80: Installing The Front Wheel

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

  • Page 81: Removing The Rear Wheel

    WHEELS, TIRES 15 – 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 82: Installing The Rear Wheel

    15 WHEELS, TIRES 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 83 WHEELS, TIRES 15 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 84: Checking The Rear Hub Damping Rubber Pieces

    15 WHEELS, TIRES 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 85: 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 86: 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 87 WHEELS, TIRES 15 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 88: Electrical System

    16 ELECTRICAL SYSTEM 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 89: Installing The 12-V Battery

    ELECTRICAL SYSTEM 16 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 90: Charging The 12-V Battery

    16 ELECTRICAL SYSTEM – 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 91 ELECTRICAL SYSTEM 16 Preparatory work – Remove the passenger seat. ( p. 63) 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 92: Changing The Main Fuse

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

  • Page 93: Changing The Abs Fuses

    ELECTRICAL SYSTEM 16 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 94: Changing The Fuses Of Individual Electrical Power Consumers

    16 ELECTRICAL SYSTEM 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 95: Loosening The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 16 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 96: Removing The Cover Of The Headlight Mask Rack

    16 ELECTRICAL SYSTEM – Mount adjusting screw V01212-11 Finishing work – Check the headlight setting. ( p. 95) 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 97: Installing The Cover Of The Headlight Mask Rack

    ELECTRICAL SYSTEM 16 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 98: Adjusting The Headlight Range

    A diagnosis adapter has been connected in the factory for con- nection with diagnosis interface which applies to all manufac- turers. Info Remove the diagnosis adapter to use the KTM diagno- sis tool. Following completion of the diagnostics, plug the diag- H02681-10...

  • Page 99: Front Acc1 And Acc2

    ELECTRICAL SYSTEM 16 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 100: Cooling System

    17 COOLING SYSTEM 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 101: Compensating Tank

    COOLING SYSTEM 17 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: V01255-10 –...

  • Page 102: Draining The Coolant

    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 103: Filling/Bleeding The Cooling

    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 104: Changing The Coolant

    17 COOLING SYSTEM – 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 1.4 l (1.5 qt.) Coolant ( p.
  • Page 105 COOLING SYSTEM 17 – 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 106: Tuning The Engine

    18 TUNING THE ENGINE 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 107: Slip Adjustment

    TUNING THE ENGINE 18 18.3 Slip adjustment The slip adjustment 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 108: Service Work On The Engine

    19 SERVICE WORK ON THE ENGINE 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 109 SERVICE WORK ON THE ENGINE 19 – 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 110: Adding Engine Oil

    127) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. H01066-10 KTM recommends changing the engine oil where neces- sary. – Mount and tighten filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 111: Checking The Free Travel Of The Clutch Lever

    SERVICE WORK ON THE ENGINE 19 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 112: Cleaning, Care

    20 CLEANING, CARE 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 113: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 20 – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 65) – 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 114: Storage

    – 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. 61) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 115: Preparing For Use After Storage

    STORAGE 21 21.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 62) – Remove the rear of the motorcycle from the lifting gear. p. 61) – Charge the 12-V battery. p. 88) –...

  • Page 116: Troubleshooting

    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 117 – 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 118: Technical Data

    23 TECHNICAL DATA 23.1 Engine Design 2-cylinder 4-stroke in-line engine, water-cooled Displacement 799 cm³ (48.76 cu in) Stroke 65.7 mm (2.587 in) Bore 88 mm (3.46 in) Compression ratio 12.7:1 Control DOHC, 4 valves per cylinder controlled via cam lever, chain drive Valve diameter, intake 36 mm (1.42 in)

  • Page 119: Engine Tightening Torques

    TECHNICAL DATA 23 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 120 23 TECHNICAL DATA 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) Loctite ® 243™ Screw, oil pump unit 10 Nm (7.4 lbf ft) Screw, oil/water heat exchanger 10 Nm (7.4 lbf ft) Loctite...

  • Page 121: Capacities

    TECHNICAL DATA 23 Spark plug 11 Nm (8.1 lbf ft) Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) Screw plug, bearing support M10x1 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw plug, cam lever axis M10x1 8 Nm (5.9 lbf ft) Screw, unlocking of timing chain M10x1 8 Nm (5.9 lbf ft)

  • Page 122: Chassis

    23 TECHNICAL DATA Fuel tank capacity, approx. 14 l (3.7 US gal) Super unleaded (ROZ 95) p. 128) 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tub- ing, powder-coated Fork WP Suspension Up Side Down 4357 Shock absorber WP Suspension 4614 Suspension travel front...

  • Page 123: Electrical System

    180/55 ZR 17 M/C (73W) TL (G) MAXXIS Supermaxx ST MAXXIS Supermaxx ST The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: KTM.com 23.7 Fork Fork article number 0636C126T301112...

  • Page 124: Chassis Tightening Torques

    23 TECHNICAL DATA 23.9 Chassis tightening torques EJOTPT Remaining screws, chassis ® K45x12 1 Nm (0.7 lbf ft) EJOTPT Remaining screws, chassis ® K50x12 1 Nm (0.7 lbf ft) EJOTPT ® Remaining screws, chassis K50x14 1 Nm (0.7 lbf ft) Remaining screws, chassis EJOTPT ®...
  • Page 125 TECHNICAL DATA 23 Screw, foot brake lever stub 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, fuel tank bracket 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, fuel tank spoiler 3 Nm (2.2 lbf ft) Screw, ground wire on frame 6 Nm (4.4 lbf ft) Screw, ground wire to starter motor 10 Nm (7.4 lbf ft)
  • Page 126 23 TECHNICAL DATA Screw, grab handle M8x50 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, main silencer fastening 15 Nm (11.1 lbf ft) Screw, passenger seat bracket 25 Nm (18.4 lbf ft) Loctite ®...
  • Page 127 TECHNICAL DATA 23 Lambda sensor M18x1.5 50 Nm (36.9 lbf ft) Adjusting screw, swingarm M20LHx1.5 10 Nm (7.4 lbf ft) Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread and contact area of wheel spindle greased Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft) Thread greased...

  • Page 128: Declarations Of Conformity

    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 129: Substances

    SUBSTANCES 25 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 130 25 SUBSTANCES Fork oil (SAE 5) Standard/classification – SAE ( p. 130) (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 131: Checking The Antifreeze And Coolant

    AUXILIARY SUBSTANCES 26 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 132: 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 133: 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 134: 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 135: List Of Symbols

    104) 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. 49) is activated.

  • Page 136: Index

    Anti-lock braking system ....70 KTM MY RIDE ..... . . 37 Language .
  • Page 137 INDEX Coolant Fuel tank filler cap draining ......100 closing ......17 opening .
  • Page 138 INDEX Spare parts ......9 Start button ......16 Oil filter Starting .
  • Page 139 *3214299en* 3214299en 03/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.com...

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