KTM 890 DUKE R Owner's Manual
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KTM 890 DUKE R Owner's Manual

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OWNER'S MANUAL
2022
890 DUKE R
Art. no. 3214544en

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Summary of Contents for KTM 890 DUKE R

  • Page 1 OWNER'S MANUAL 2022 890 DUKE R Art. no. 3214544en...
  • 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........18 Symbols used ........5 6.5.1 Start button/emergency OFF Formats used........5 switch......... 18 Ignition and steering lock....19 SAFETY ADVICE..........6 Opening fuel tank filler cap....
  • Page 5 Quickshifter + (optional)....41 the fork........... 65 7.16.31 Shift Light ........41 12.4 Compression damping of the shock 7.16.32 KTM MY RIDE (optional) ....42 absorber.......... 65 7.16.33 Pairing (optional) ......42 12.5 Adjusting the low-speed 7.16.34 Audio player (optional) ....43 compression damping of the shock 7.16.35...
  • Page 6 TABLE OF CONTENTS 15 WHEELS, TIRES ......... 86 19.3 Adding engine oil ......117 19.4 Checking the free travel of the 15.1 Removing the front wheel ....86 clutch lever ........118 15.2 Installing the front wheel ....87 19.5 Setting the free travel of the clutch 15.3 Removing the rear wheel...

  • Page 7: Means Of Representation 1

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special 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

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
  • Page 11 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 (example) F03619-10 Combination instrument ( p. 23) Ignition and steering lock ( p. 19) Clutch lever ( p. 15) Seat lock ( p. 20) Side stand ( p. 22) Shift lever ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) F03620-10 Tool set ( p. 21) Fuel tank filler cap Combination switch ( p. 15) Start button/emergency OFF switch ( p. 18) Hand brake lever ( p. 15) Level viewer, engine oil Foot brake lever ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 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 16: Fork Part Number

    5 SERIAL NUMBERS 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 attached the top of the shock absorber. F02735-10 Steering damper article number Steering damper article number is embossed on the underside of the steering damper.

  • Page 17: Controls 6

    CONTROLS 6 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. K01350-10 Throttle grip The throttle grip...

  • Page 18: Light Switch

    6 CONTROLS 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 19 CONTROLS 6 To switch off the cruise control system function, press the cruise control system tip switch to the left. In addition, the cruise control system function is deactivated when one of the following events occurs: – Operating the hand brake lever –...

  • Page 20: Menu Buttons

    6 CONTROLS 6.4.4 Menu buttons The menu buttons are fitted in the middle of the left combination switch. The menu buttons are used to control the display on the combina- tion instrument. Button is the UP button. Button is the DOWN button. Button is the SET button.

  • Page 21: Ignition And Steering Lock

    CONTROLS 6 Start button/emergency OFF switch on (middle posi- tion) – This position is required for operation; the igni- tion circuit is closed. Starter motor on (lower position) – In this position, the starter motor is actuated. Ignition and steering lock The ignition and steering lock is located in front of the upper triple clamp.

  • Page 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Lift cover of the fuel tank filler cap and insert the ignition key into the lock. Note Danger of damage The ignition key may break if overloaded. Damaged ignition keys must be replaced. – Push down on the fuel tank filler cap to take pressure off the ignition key.

  • Page 23: Tool Set

    If you carry a passenger, the passenger can hold onto the grab handles during the trip. Info The vehicle has been set up in the factory for one-person operation. Only an authorized KTM workshop may carry out the conversion. The components for one-person operation and for operation K01355-10 with a passenger are included in the scope of supply.

  • Page 24: Shift Lever

    6 CONTROLS 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 25: Combination Instrument 7

    (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 26: Warnings

    7 COMBINATION INSTRUMENT 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 27 113) 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. 53) is activated.

  • Page 28: Display

    7 COMBINATION INSTRUMENT 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. 27) Cruise control indicator (optional) ( p. 28) Bluetooth ®...

  • Page 29: Track Display (Optional)

    COMBINATION INSTRUMENT 7 TRACK Display (optional) F02748-10 Info The figure shows the start screen of the combination instrument in active riding mode TRACK (optional). If the menu is opened, the speed is still displayed. Throttle response (optional) ( p. 114) Slip adjustment (optional) ( p.

  • Page 30: Cruise Control Indicator (Optional)

    7 COMBINATION INSTRUMENT 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. 16). F02755-10 7.10 Fuel level display The fuel level indicator consists of bars.

  • Page 31: Trip Odometer

    COMBINATION INSTRUMENT 7 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 32: Menu

    7 COMBINATION INSTRUMENT 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 33: Trip 2

    COMBINATION INSTRUMENT 7 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 34: Settings

    ® 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 35: Temperature

    COMBINATION INSTRUMENT 7 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 36: 7.16.11 Language

    7 COMBINATION INSTRUMENT 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 37: 7.16.14 Tpms Warning

    Make sure that the daytime running light is deac- tivated with the diagnostics tool when the menu item is not available, but the low beam is required. (Your authorized KTM workshop will be glad to help.) – Note the legal regulations regarding the daytime running light.

  • Page 38: Quick Selector 1

    7 COMBINATION INSTRUMENT 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 39: 7.16.17 Set Favorites

    COMBINATION INSTRUMENT 7 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 40: 7.16.20 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 41: Track (Optional)

    COMBINATION INSTRUMENT 7 Info Do not open the throttle during the selection. 7.16.23 Track (optional) Condition • The drive mode TRACK (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 42: Heated Grips (Optional)

    7 COMBINATION INSTRUMENT 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 43: 7.16.29 Abs Mode

    COMBINATION INSTRUMENT 7 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 44: 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 45: 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 46: 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 47: 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 48: 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 49: Adjusting The Basic Position Of The Foot Brake Lever

    ERGONOMICS 8 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 50: Checking The Basic Position Of The Shift Lever

    8 ERGONOMICS Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause a malfunction of the quickshifter + (optional).

  • Page 51: 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 52: Running In The Engine

    9 PREPARING FOR USE – Run the engine in. ( p. 50) 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 53 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 54: 10 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 55: Starting Off

    RIDING INSTRUCTIONS 10 The ABS warning lamp lights up and goes back out after starting off. – Shift the transmission to neutral position. The green idle indicator lamp N lights up. – Press the start button/emergency OFF switch into the lower position Info Only press the start button/emergency OFF switch into...

  • Page 56: Quickshifter + (Optional)

    10 RIDING INSTRUCTIONS Condition The drive mode TRACK (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 57 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 58 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 59: 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 60: 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 61: 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 62: Transporting

    10 RIDING INSTRUCTIONS 10.11 Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. 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.

  • Page 63: Refueling

    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 64: 11 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 65: 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 66: 12 Tuning The Chassis

    12 TUNING THE CHASSIS 12.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .

  • Page 67: Adjusting The Rebound Damping Of The Fork

    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.)

  • Page 68: 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 69: 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 70 12 TUNING THE CHASSIS Main work – Turn adjusting screw counterclockwise all the way. – Turn it clockwise by the number of turns corresponding to the shock absorber type and use. Guideline Spring preload - Preload Adjuster Comfort 1 turn Standard 3 turns F02741-10...

  • Page 71: 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 72: Taking The Motorcycle Off The Front Lifting Gear

    13 SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Align the lifting gear at the front with the adapters to the fork legs. Front wheel work stand, small (61129965100) Info Always raise the motorcycle at the rear first. Pay attention to the brake lines.

  • Page 73: Removing The Passenger Seat

    Remove the ignition key from the seat lock. Info The vehicle has been set up in the factory for one- person operation. Only an authorized KTM workshop may carry out the conversion. K01359-10 The components for one-person operation and for oper- ation with a passenger are included in the scope of supply.

  • Page 74: Mounting The Passenger Seat

    Finally, check that the passenger seat is correctly mounted. Info The vehicle has been set up in the factory for one- person operation. Only an authorized KTM workshop may carry out the conversion. The components for one-person operation and for oper- ation with a passenger are included in the scope of supply.

  • Page 75: 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 76: 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 77: 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 78: 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 79 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 80 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 81: 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 82: 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 83: 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 84: 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 85: Checking 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 the vehicle upright.

  • Page 86: 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 87: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake 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 88: 15 Wheels, Tires

    15 WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 69) – Lift the motorcycle with the front lifting gear. ( p. 69) Main work – Remove screw and pull wheel speed sensor out of the hole.

  • Page 89: 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 90: 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 91: 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 92 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 93: 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 94: 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 95: 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 96 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 97: Electrical System 16

    Make sure that the daytime running light is deacti- vated with the diagnostics tool when the menu item is not available, but the low beam is required. (Your authorized KTM workshop will be glad to help.) – Note the legal regulations regarding the daytime run- ning light.

  • Page 98: 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 99: 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 100 16 ELECTRICAL SYSTEM Preparatory work – Remove the passenger seat. ( p. 71) 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. Connect the battery charger to the mains connection.

  • Page 101: 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 102: 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 103: 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 104: 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 105: Removing The Cover Of The Headlight Mask Rack

    ELECTRICAL SYSTEM 16 – Mount adjusting screw F02770-11 Finishing work – Check the headlight setting. ( p. 104) 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 106: 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 107: 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 108: 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 109: 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 110: 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: K01373-10 –...

  • Page 111: 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 112: 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 113: 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 114 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 115: 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 116: Slip Adjustment (Optional)

    18 TUNING THE ENGINE 18.3 Slip adjustment (optional) 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 117: 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 118 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 119: Adding Engine Oil

    137) 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 120: 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 121: 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 122: 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. 74) – 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 123: 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. 69) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 124: Preparing For Use After Storage

    21 STORAGE 21.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 70) – Remove the rear of the motorcycle from the lifting gear. p. 69) – Charge the 12-V battery. p. 97) –...

  • Page 125: 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 126 – 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 127: 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 128: 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 129 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 130: 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 131: 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. 138) 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tub- ing, powder-coated WP APEX 3343 Fork...

  • Page 132: Electrical System

    180/55 ZR 17 M/C (73W) TL Michelin Power Cup 2 Michelin Power Cup 2 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 05.58.8T.49...

  • Page 133: Shock Absorber

    TECHNICAL DATA 23 23.8 Shock absorber Shock absorber article number 15.18.7T.49 WP APEX 5746 Shock absorber Low-speed compression damping Comfort 16 clicks Standard 14 clicks Sport 10 clicks Full payload 14 clicks High-speed compression damping Comfort 1.5 turns Standard 1.5 turns Sport 1.5 turns Full payload...
  • Page 134 23 TECHNICAL DATA Remaining screws, chassis 3 Nm (2.2 lbf ft) Screw, fixed grip, left 3 Nm (2.2 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, air filter box 3 Nm (2.2 lbf ft) Screw, brake fluid reservoir for rear 5 Nm (3.7 lbf ft)
  • Page 135 TECHNICAL DATA 23 Screw, front rider's seat 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, fuel tank rollers 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 136 23 TECHNICAL DATA Screw, front brake disc 28 Nm (20.7 lbf ft) Loctite ® 2701™ 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, main silencer holder M8x25 25 Nm (18.4 lbf ft)
  • Page 137 TECHNICAL DATA 23 Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite ® 243™ Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Screw, swingarm pivot 100 Nm (73.8 lbf ft) Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ®...

  • Page 138: 24 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 139: Substances 25

    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 140 25 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 140) (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 141: Auxiliary Substances 26

    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 142: 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 143: Index Of Special Terms 28

    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 144: 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 145: List Of Symbols 30

    113) 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. 53) is activated.

  • Page 146: Index

    ......80 KTM MY RIDE ..... . . 42 Brake fluid Language .
  • Page 147 INDEX Trip 2 ......31 Free travel of clutch lever warnings ..... . . 24, 38 checking .
  • Page 148 INDEX Safe operation ......7 Main fuse Seat lock ......20 changing .
  • Page 149 INDEX Troubleshooting ....123-124 Turn signal switch ..... . . 18 Type label .
  • Page 150 *3214544en* 3214544en 10/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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