KTM RC 390 2018 Owner's Manual
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KTM RC 390 2018 Owner's Manual

KTM RC 390 2018 Owner's Manual

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OWNER'S MANUAL
2018
RC 390
Art. no. 3213560en

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Summary of Contents for KTM RC 390 2018

  • Page 1 OWNER'S MANUAL 2018 RC 390 Art. no. 3213560en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS CONTROLS..............22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Clutch lever............22 Symbols used ............7 Hand brake lever..........22 Formats used............8 Throttle grip ............23 SAFETY ADVICE.............. 9 Horn button............23 Use definition............9 Light switch ............
  • Page 6 TABLE OF CONTENTS Activation and test ..........38 10 RIDING INSTRUCTIONS..........63 Warning notes............ 39 10.1 Checks and maintenance when preparing for use ..............63 Function buttons..........42 10.2 Starting............. 64 Indicator lamps..........43 10.3 Starting off............66 Display ............. 44 10.4 Shifting, riding ..........
  • Page 7 TABLE OF CONTENTS 13.12 Checking the chain tension ......... 88 15.5 Checking the rear hub rubber dampers ... 124 13.13 Adjusting the chain tension......... 90 15.6 Checking the tire condition ....... 125 13.14 Checking the chain, rear sprocket, and engine 15.7 Checking the tire air pressure......
  • Page 8 TABLE OF CONTENTS 19 SERVICE WORK ON THE ENGINE ........ 159 27 INDEX OF SPECIAL TERMS ......... 192 19.1 Checking the engine oil level......159 28 LIST OF ABBREVIATIONS..........193 19.2 Changing the engine oil and oil filter, cleaning 29 LIST OF SYMBOLS............194 the oil screens ..........

  • Page 9: Means Of Representation

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

  • Page 10: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 11: Safety Advice

    SAFETY ADVICE Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.

  • Page 12: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 13: Safe Operation

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride 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 14: 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 Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe- ses.

  • Page 15: Owner's Manual

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 16: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 17: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 18: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) V00618-10...
  • Page 19 VIEW OF VEHICLE High beam flasher button ( p. 24) Light switch ( p. 24) Horn button ( p. 23) Turn signal switch ( p. 25) Clutch lever ( p. 22) Filler cap Seat lock ( p. 30) Shift lever ( p.

  • Page 20: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) V00617-10...
  • Page 21 VIEW OF VEHICLE Grab handles ( p. 31) Tool set ( p. 30) Ignition/steering lock ( p. 26) Electric starter button ( p. 26) Emergency OFF switch ( p. 25) Throttle grip ( p. 23) Hand brake lever ( p. 22) Foot brake lever ( p.

  • Page 22: Serial Numbers

    SERIAL NUMBERS Chassis number The vehicle chassis number is stamped on the frame behind the steering head on the right. 0 0 1 402174-10 Type label The type label is located on the right side of the frame. H01135-10...

  • Page 23: Engine Number

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

  • Page 24: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. K00697-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. K00703-10...

  • Page 25: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. K00703-11 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. •...

  • Page 26: Light Switch

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

  • Page 27: Turn Signal Switch

    CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal, right, on –...

  • Page 28: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button K00707-10 6.10 Ignition/steering lock...

  • Page 29: Locking The Steering

    CONTROLS 6.11 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar all the way to the left. –...

  • Page 30: Opening The Filler Cap

    CONTROLS 6.13 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 31: Closing The Filler Cap

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

  • Page 32: Seat Lock

    CONTROLS 6.15 Seat lock The seat lock is located to the left of the seat. The seat lock can be unlocked using the ignition key. K00708-10 6.16 Tool set The tool set is in the storage compartment under the seat. K00709-10...

  • Page 33: Grab Handles

    CONTROLS 6.17 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. K00705-10 6.18 Passenger footrests The passenger footrests can be folded in and out. Possible states Passenger footrests folded up –...

  • Page 34: Shift Lever

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

  • Page 35: Foot Brake Lever

    CONTROLS 6.20 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10 6.21 Side stand The side stand is on the left side of the vehicle. The side stand is used to park the motorcycle.

  • Page 36: Ergonomics

    ERGONOMICS Adjusting the basic position of the hand brake lever – Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel Info Push the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding.

  • Page 37: Adjusting The Shift Lever

    ERGONOMICS Adjusting the shift lever Info The adjustment range of the shift lever is limited. – Loosen nut , holding threaded rod Info has a left-handed thread. – Loosen nut , holding threaded rod – Adjust the shift lever by turning shift rod Guideline 150…...
  • Page 38 ERGONOMICS – Tighten nut , holding threaded rod Guideline Nut, shift rod M6LH 10 Nm (7.4 lbf ft) – Check the shift lever to ensure it is functioning properly and can move freely.

  • Page 39: Combination Instrument

    COMBINATION INSTRUMENT Overview Display ( p. 44) Function buttons ( p. 42) Info display ( p. 48) Indicator lamps ( p. 43) 401685-10...

  • Page 40: Activation And Test

    COMBINATION INSTRUMENT Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up briefly.

  • Page 41: Warning Notes

    COMBINATION INSTRUMENT Warning notes Low Oil Pressure appears on the info display if the oil pressure is too low. 401309-01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark. 401310-01...
  • Page 42 COMBINATION INSTRUMENT High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 110 °C (230 °F) 401311-01 Side Stand Down appears on the info display if the side stand is folded down. 401312-01 Low Battery appears on the info display if the battery voltage falls below the specified value.
  • Page 43 COMBINATION INSTRUMENT Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment. 401461-01...

  • Page 44: Function Buttons

    COMBINATION INSTRUMENT Function buttons You can change the display mode with the MODE button Possible display modes are total distance traveled (TRIP 1), distance 1 (ODO) and distance 2 (TRIP 2). Pressing and holding the SET button resets distance 1 (TRIP 1) and distance 2 (TRIP 2) functions to 0.0 and briefly pressing the SET button changes the info display to the next display mode.

  • Page 45: Indicator Lamps

    COMBINATION INSTRUMENT Indicator lamps Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. Malfunction indicator lamp lights up yellow – The OBD has detected an emission- or safety-critical fault. The shift warning lights up/flashes red –...

  • Page 46: Display

    COMBINATION INSTRUMENT Display is shown in kilometers per hour km/h or in miles per hour mph. The speed The tachometer shows the engine speed in revolutions per minute. The gear display shows the engaged gear. The coolant temperature appears in segment The time appears in segment The filling level in the fuel tank is displaced in segment The info display...

  • Page 47: Filling Level Display Of The Fuel Tank

    COMBINATION INSTRUMENT Filling level display of the fuel tank The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank. 401292-01...

  • Page 48: Trip F Display

    COMBINATION INSTRUMENT TRIP F display If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note Low Fuel Level appears on the info display.

  • Page 49: Coolant Temperature Indicator

    COMBINATION INSTRUMENT Coolant temperature indicator The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Coolant Temperature. Possible states Engine cold –...

  • Page 50: Info Display

    COMBINATION INSTRUMENT 8.10 Info display Various warning notes appear on info display If the general warning lamp lights up, the corresponding warning note is shown on the info display. 401291-10...

  • Page 51: Riding Time/Average Speed Menu

    COMBINATION INSTRUMENT 8.11 Riding time/average speed menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed in this menu.

  • Page 52: Average Fuel Consumption 1/Average Fuel Consumption 2 Menu

    COMBINATION INSTRUMENT In this menu, the average speed and the average fuel consumption 1 are displayed in L/100 km (or L/100 miles). Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on. If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0.

  • Page 53: Average Fuel Consumption 2/Service Menu

    COMBINATION INSTRUMENT Press the SET button Next display mode on the info display briefly. 8.14 Average fuel consumption 2/service menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. •...

  • Page 54: Service/Range Menu

    COMBINATION INSTRUMENT 8.15 Service/range menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next service and the range.

  • Page 55: Range/Riding Time Menu

    COMBINATION INSTRUMENT 8.16 Range/riding time menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displayed in this menu.

  • Page 56: Total Distance Menu Odo

    COMBINATION INSTRUMENT 8.17 Total distance menu ODO Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered.

  • Page 57: Distance Menu 1 Trip 1

    COMBINATION INSTRUMENT 8.18 Distance menu 1 TRIP 1 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. TRIP 1shows the distance since the last reset, such as between two refueling stops.

  • Page 58: Setting Kilometers Or Miles

    COMBINATION INSTRUMENT Press the SET button Display of TRIP 2 is reset for 5 - 10 seconds. Press the MODE but- Next display mode on the display ton. 8.20 Setting kilometers or miles Info Make the country-specific setting. Condition The ignition is on. The motorcycle is stationary.

  • Page 59: Setting The Time

    COMBINATION INSTRUMENT 8.21 Setting the time Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE and SET buttons for 5 - 10 seconds. The time display begins to flash.

  • Page 60: Adjusting The Shift Speed Rpm 2

    COMBINATION INSTRUMENT Info The MODE button increases the value. The SET button decreases the value. – Do not activate the two buttons for approx. 15 seconds. The display RPM 1 goes out and the set speed is stored. 8.23 Adjusting the shift speed RPM 2 Condition The ignition is on.

  • Page 61: Preparing For Use

    Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling characteristic. – Only use tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened.

  • Page 62: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 63: Loading The Vehicle

    PREPARING FOR USE Loading the vehicle Warning Danger of accidents Total weight and axle loads influence the handling characteristic. The overall weight consists of: motorcycle ready for operation and with a full tank, driver and passenger with protective clothing and helmet, and luggage. –...
  • Page 64 PREPARING FOR USE – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.)

  • Page 65: Riding Instructions

    RIDING INSTRUCTIONS 10.1 Checks and maintenance 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 used. – Check the engine oil level. ( p.

  • Page 66: Starting

    RIDING INSTRUCTIONS 10.2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing.
  • Page 67 RIDING INSTRUCTIONS – Unlock the steering. ( p. 27) – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 68: Starting Off

    RIDING INSTRUCTIONS Switching off ABS Condition Vehicle stationary, engine running. Warning Voiding of the government approval for road use and the insurance cover- age 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 69 RIDING INSTRUCTIONS Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. – Do not change into a low gear at high engine speed. Warning Danger of accidents An incorrect ignition key position causes malfunctions. –...
  • Page 70 – Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

  • Page 71: Applying The Brakes

    Warning 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.)
  • Page 72 RIDING INSTRUCTIONS Warning Danger of accidents The brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously. – Take your foot off the foot brake lever when you are not braking. Warning Danger of accidents Higher total weight increases the stopping distance.

  • Page 73: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents The rear wheel can lock due to the engine braking effect. – Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground. Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. –...

  • Page 74: Transport

    RIDING INSTRUCTIONS Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. – Park the vehicle on a firm and level surface. –...

  • Page 75: Refueling

    RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. – Switch off the engine and remove the ignition key.
  • Page 76 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.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.
  • Page 77 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 28) – Fill the fuel tank with fuel up to the lower edge of the fuel filler. Total fuel tank 9.5 l (2.51 US gal) Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 78: Service Schedule

    15,000 km (9,300 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ● Check that the electrical system is functioning properly. ○...
  • Page 79 Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 80: Recommended Work

    SERVICE SCHEDULE 11.3 Recommended work Every four years Every year every 30,000 km (18,600 mi) every 7,500 km (4,650 mi) after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ● ● Check the swingarm bearing. ● ●...

  • Page 81: Tuning The Chassis

    TUNING THE CHASSIS 12.1 Adjusting the spring pretension of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring pretension defines the initial status of the spring operation on the shock absorber.

  • Page 82: Service Work On The Chassis

    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 83: Lifting The Motorcycle With The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the vehicle on side stand – Remove bushings kit. 402029-10 13.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over.

  • Page 84: Taking The Motorcycle From The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Position the lifting gear. Mounting pin (69329965030) Lifting gear, front (69329965000) Info Always raise the motorcycle at the rear first. – Raise the motorcycle at the front. 402345-01 13.4 Taking the motorcycle from the front lifting gear...

  • Page 85: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS – Mount protection cap V00600-10 Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 80) 13.5 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the rear lifting gear. ( p.

  • Page 86: Removing The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 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 87: Mounting The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 13.7 Mounting the front rider's seat – Attach recesses on the front rider's seat to the fuel tank, push the front rider's seat forward, and lower at the rear. The pin locks audibly in place. –...

  • Page 88: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS 13.9 Mounting the passenger seat Main work – Attach hook into bracket – Lower the passenger seat and push back. K00021-10 – Mount and tighten screw with the washer. Guideline Screw, passenger seat 7 Nm (5.2 lbf ft) Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 89: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 13.10 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 87) 400678-01 13.11 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...

  • Page 90: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 80) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –...
  • Page 91 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 80) Main work – Shift gear to neutral. – In the area of the chain sliding guard, press the chain upward toward the swingarm and determine chain tension Info Upper chain section...

  • Page 92: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 13.13 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly.
  • Page 93 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks...

  • Page 94: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 13.14 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 80) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 95 SERVICE WORK ON THE CHASSIS – Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure distance of 20 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.

  • Page 96: Removing The Battery Cover

    SERVICE WORK ON THE CHASSIS Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p. 80) 13.15 Removing the battery cover Preparatory work – Remove the front rider's seat. ( p. 84) Main work – Pull loop toward the rear.

  • Page 97: Mounting The Battery Cover

    SERVICE WORK ON THE CHASSIS 13.16 Mounting the battery cover Main work – Position battery cover and pull toward the rear. The battery cover engages with an audible click. – Check the battery cover is seated correctly. K00712-10 Finishing work –...
  • Page 98 SERVICE WORK ON THE CHASSIS – Remove screws V00604-10 – Remove screws – Take off the front spoiler. V00605-11...

  • Page 99: Fitting Front Spoiler

    SERVICE WORK ON THE CHASSIS 13.18 Fitting front spoiler – Position the front spoiler. – Mount and tighten screws Guideline Screw, front spoiler rear 6 Nm (4.4 lbf ft) V00605-10 – Mount and tighten screws Guideline Screw, front spoiler top front 7 Nm (5.2 lbf ft) V00604-11...

  • Page 100: Removing The Left Side Cover

    SERVICE WORK ON THE CHASSIS – Press lightly on the side cover in the area in order to snap the side cover on. The holding lugs engage in the holes on the front spoiler. K00715-10 13.19 Removing the left side cover –...
  • Page 101 SERVICE WORK ON THE CHASSIS – Remove expanding rivet V00607-10 – Swing the side cover outward. – Pull hose out of hose guide – Detach active carbon filter Info The assistance of a second person can be useful. – Take off the side cover. V00622-10...

  • Page 102: Installing The Left Side Cover

    SERVICE WORK ON THE CHASSIS 13.20 Installing the left side cover – Position activated charcoal filter Info The assistance of a second person can be useful. – Position hose in hose guide V00622-11 – Position the side cover. – Mount and tighten screws Guideline Screw, side cover 6 Nm (4.4 lbf ft)

  • Page 103: Removing The Right Side Cover

    SERVICE WORK ON THE CHASSIS – Mount expanding rivet V00607-11 13.21 Removing the right side cover – Remove screws – Remove screws – Pull off holding lug in area K00714-10...

  • Page 104: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS – Remove expanding rivet – Take off the side cover. V00606-10 13.22 Installing the right side cover – Position the side cover. – Mount and tighten screws Guideline Screw, side cover 6 Nm (4.4 lbf ft) –...
  • Page 105 SERVICE WORK ON THE CHASSIS – Mount expanding rivet V00606-10...

  • Page 106: Brake System

    – Only use spare parts on the brake system which have been approved and recom- mended by KTM. – Only use tires/wheels approved by KTM with the corresponding speed index. – Maintain the specified tire air pressure. – Service work and repairs must be performed professionally. (Your authorized KTM workshop will be glad to help.)

  • Page 107: Checking The Brake Discs

    The ABS warning lamp goes out when you start off. 14.2 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 108: Checking The Brake Fluid Level Of The Front Brake

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

  • Page 109: Adding Front Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 110 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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 111: 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. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.

  • Page 112: Checking The Rear Brake Fluid Level

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.

  • Page 113: Adding Rear Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 114 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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 115: Checking The Rear Brake Linings

    7 Nm (5.2 lbf ft) rear brake H01142-10 14.8 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.)

  • Page 116: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed. –...

  • Page 117: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) »...
  • Page 118 BRAKE SYSTEM – Detach spring – Release nut and use screw to adjust the specified free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The range of adjustment is limited. – Hold screw and tighten nut –...

  • Page 119: Wheels, Tires

    WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 80) – Lift the motorcycle with the front lifting gear. ( p. 81) Main work – Remove screws , take off reflector and push the fender to the side. –...

  • Page 120: Installing The Front Wheel

    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. Main work –...
  • Page 121 WHEELS, TIRES – Clean the thread of the wheel spindle and screw – Clean and grease wheel spindle. Long-life grease ( p. 189) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Tighten screws Guideline Screw, fork stub...

  • Page 122: Removing The Rear Wheel

    WHEELS, TIRES – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Remove the rear of the motorcycle from the lifting gear. ( p.

  • Page 123: Installing The Rear Wheel

    WHEELS, TIRES Main work – Remove screw and pull wheel speed sensor out of the hole. – Remove nut with the washer. Remove chain adjuster – Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
  • Page 124 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 125 WHEELS, TIRES – Clean the thread of the wheel spindle and nut – Clean and grease wheel spindle. Long-life grease ( p. 189) – Clean the mating surfaces of the brake caliper support and swingarm. – Position the rear wheel. The brake linings are correctly positioned.

  • Page 126: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES 15.5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub become damaged. Preparatory work –...

  • Page 127: Checking The Tire Condition

    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 characteristic.
  • Page 128 DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regard- less of the actual state of wear.

  • Page 129: Checking The Tire Air Pressure

    WHEELS, TIRES 15.7 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. – Remove the dust cap. –...

  • Page 130: Electrical System

    ELECTRICAL SYSTEM 16.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –...

  • Page 131: Installing The Battery

    ELECTRICAL SYSTEM – Pull back positive terminal cover – Disconnect positive cable from the battery. – Detach rubber band – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged.

  • Page 132: Recharging The Battery

    ELECTRICAL SYSTEM – Position negative cable ; mount and tighten the screw. V00620-11 Finishing work – Mount the battery cover. ( p. 95) – Mount the front rider's seat. ( p. 85) – Set the clock. ( p. 57) 16.3 Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns.
  • Page 133 ELECTRICAL SYSTEM Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the battery.
  • Page 134 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

  • Page 135: Changing The Abs Fuses

    ELECTRICAL SYSTEM 16.4 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 protective cap next to the negative terminal of the battery. These fuses protect the return pump and the hydraulic unit of the ABS.
  • Page 136 ELECTRICAL SYSTEM – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 179) Replace spare fuse in the fuse box so that it is available if needed. – Mount the protection cap. To change the fuse of the ABS return pump: –...

  • Page 137: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 16.5 Changing the fuses of individual power consumers Info The fuse box with the main fuse and fuses of the individual power consumers is located next to the positive terminal of the battery. Preparatory work – Switch off the ignition by turning the ignition key to the position –...
  • Page 138 ELECTRICAL SYSTEM Info You can recognize a faulty fuse by a burned-out fuse wire Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

  • Page 139: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM 16.6 Changing the low beam bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...
  • Page 140 ELECTRICAL SYSTEM Main work – Turn socket counterclockwise. – Pull the socket with low beam bulb out of the headlight housing. – Disconnect the socket with the low beam bulb from connector and remove. – Connect the new socket with the low beam bulb to the connector. Low beam (H11/socket PGJ19-2) ( p.

  • Page 141: Changing The High Beam Bulb

    ELECTRICAL SYSTEM Finishing work – Check the low beam headlight adjustment. ( p. 141) 16.7 Changing the high beam bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...
  • Page 142 ELECTRICAL SYSTEM Main work – Turn socket counterclockwise. – Pull the socket with high beam bulb out of the headlight housing. – Disconnect the socket with the high beam bulb from connector and remove. – Connect the new socket with the high beam bulb to the connector. High beam (H9/socket PGJ19-5) ( p.

  • Page 143: Checking The Low Beam Headlight Adjustment

    ELECTRICAL SYSTEM Finishing work – Check the high beam headlight adjustment. ( p. 142) 16.8 Checking the low beam headlight adjustment – Position the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight.

  • Page 144: Checking The High Beam Headlight Adjustment

    ELECTRICAL SYSTEM 16.9 Checking the high beam headlight adjustment – Position the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...

  • Page 145: Adjusting The Headlight Range Of The Low Beam

    ELECTRICAL SYSTEM 16.10 Adjusting the headlight range of the low beam Main work – Adjust the beam range of the low beam by turning screw Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking the low beam headlight setting).

  • Page 146: Diagnostics Connector

    ELECTRICAL SYSTEM 16.12 Diagnostics connector Diagnostics connector is located under the front rider's seat. H01911-10...

  • Page 147: Cooling System

    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 When the temperature falls, this surplus coolant is sucked back into the cooling system.
  • Page 148 COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 402242-10...

  • Page 149: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM 17.2 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at oper- ating temperature.

  • Page 150: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Check the coolant level in the compensating tank The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: – Check the cooling system for leaks.
  • Page 151 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 152 COOLING SYSTEM – Mount the cover of the compensating tank. – Take off radiator cap – Check the antifreeze in the coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze in the coolant does not match the specified value: –...

  • Page 153: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM 17.4 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at oper- ating temperature.

  • Page 154: Draining The Coolant

    COOLING SYSTEM Main work – Remove cover of the compensating tank. – Add coolant to the MAX marking. Coolant ( p. 186) – Mount the cover of the compensating tank. V00178-11 17.5 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...
  • Page 155 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 156: Filling/Bleeding The Cooling System

    COOLING SYSTEM 17.6 Filling/bleeding the 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. –...
  • Page 157 COOLING SYSTEM – Loosen bleeder screw Guideline 3 turns – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately. Coolant ( p.
  • Page 158 COOLING SYSTEM Finishing work – Fit the front spoiler. ( p. 97) – Install the left side cover. p. 100) – Install the right side cover. p. 102)

  • Page 159: Tuning The Engine

    TUNING THE ENGINE 18.1 Checking the clutch lever play Note Clutch damage If there is no play on the clutch lever, the clutch will begin to slip. – Before operating the motorcycle, always check the clutch lever play. – Check the clutch lever for smooth operation. –...

  • Page 160: Adjusting Play In The Clutch Lever

    TUNING THE ENGINE 18.2 Adjusting play in the clutch lever – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen lock nut – Adjust the play in the clutch level by turning adjusting screw Guideline 1… 3 mm (0.04… 0.12 in) Clutch lever play –...

  • Page 161: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 19.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the markings .
  • Page 162 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regula- tions. Info Drain the engine oil while the engine is at operating temperature. Preparatory work –...
  • Page 163 SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove oil drain plug with the O-ring. – Remove oil screen with the O-ring. – Remove screw plug with oil screen – Completely drain the engine oil. –...
  • Page 164 SERVICE WORK ON THE ENGINE – Insert new oil filter – Lubricate the O-ring of the oil filter cover. Mount oil filter cover – Mount and tighten the screws. Guideline Screw, oil filter cover 12 Nm (8.9 lbf ft) Info Too little engine oil or poor-quality engine oil results in premature wear of the L02271-10 engine.

  • Page 165: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 19.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil.

  • Page 166: Cleaning, Care

    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 167 CLEANING, CARE – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a paint- brush. Motorcycle cleaner ( p.

  • Page 168: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE – Clean the chain. ( p. 87) – Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials. Preserving materials for paints, metal and rubber ( p. 190) – Treat all painted parts with a mild paint polish. Perfect Finish and high gloss polish for paints ( p.
  • Page 169 CLEANING, CARE – Clean the motorcycle. ( p. 164) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.

  • Page 170: Storage

    0… 35 °C (32… 95 °F) direct sunlight – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 80)

  • Page 171: Preparing For Use After Storage

    STORAGE – Lift the motorcycle with the front lifting gear. ( p. 81) – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 172: Troubleshooting

    Operating error Carry out the start procedure. ( p. 64) – Fault in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter is very dirty Change the air filter.
  • Page 173 TROUBLESHOOTING Faults Possible cause Action – Malfunction indicator lamp lights up Fault in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during the trip Lack of fuel Refuel. ( p. 73) –...
  • Page 174 TROUBLESHOOTING Faults Possible cause Action – The combination instrument shows Fuse 7 is blown Change the fuses of individual power consumers. nothing on the display p. 135) – Set the clock. ( p. 57) – Speedometer in combination instru- Speedometer wiring harness is dam- Check the wiring harness and plug-in connector.

  • Page 175: Technical Data

    TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 373 cm³ (22.76 cu in) Stroke 60 mm (2.36 in) Bore 89 mm (3.5 in) Compression ratio 12.6:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 36 mm (1.42 in) Valve diameter, exhaust 29 mm (1.14 in)

  • Page 176: Engine Tightening Torques

    TECHNICAL DATA 4th gear 21:24 5th gear 23:22 6th gear 25:21 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 296 W Spark plug BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm (0.04 in) Cooling...
  • Page 177 TECHNICAL DATA – Screw, alternator cover 12 Nm (8.9 lbf ft) Screw, bearing retainer 12 Nm (8.9 lbf ft) Loctite ® 243™ – Screw, camshaft bearing support 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, camshaft, decompression shaft 10 Nm (7.4 lbf ft) Screw, chain securing guide 10 Nm (7.4 lbf ft) Loctite...
  • Page 178 TECHNICAL DATA – Screw, water pump cover 12 Nm (8.9 lbf ft) – Nut, exhaust flange 22 Nm (16.2 lbf ft) – Nut, manifold on cylinder head 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw plug 12 Nm (8.9 lbf ft) Screw, balancer shaft gear 40 Nm (29.5 lbf ft) Loctite...

  • Page 179: Capacities

    TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.7 l (1.8 qt.) Engine oil (SAE 15W/50) ( p. 187) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 186) 23.3.3 Fuel Total fuel tank capacity, approx. 9.5 l (2.51 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.
  • Page 180 TECHNICAL DATA Front 320 mm (12.6 in) Rear 230 mm (9.06 in) Brake discs - wear limit Front 4.0 mm (0.157 in) Rear 3.6 mm (0.142 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger/full payload Front 2.0 bar (29 psi)

  • Page 181: Electrical System

    TECHNICAL DATA 23.5 Electrical system Battery ETZ-9-BS Battery voltage: 12 V Nominal capacity: 8 Ah Maintenance-free Fuse 75011088005 Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Low beam H11/socket PGJ19-2 12 V 55 W High beam H9/socket PGJ19-5...

  • Page 182: Tires

    150/60 R 17 M/C 66H TL Michelin Pilot Power Street Michelin Pilot Power Street 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...

  • Page 183: Chassis Tightening Torques

    TECHNICAL DATA 23.9 Chassis tightening torques – Screw, chain guard EJOT PT ® K60x30 4 Nm (3 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) – Screw, engine electronics control unit 3 Nm (2.2 lbf ft) – Nut, chain guard 7 Nm (5.2 lbf ft) –...
  • Page 184 TECHNICAL DATA – Screw, air filter box lid 6 Nm (4.4 lbf ft) – Screw, air filter box, on frame 6 Nm (4.4 lbf ft) – Screw, battery compartment 6 Nm (4.4 lbf ft) – Screw, brake fluid reservoir, rear brake 8 Nm (5.9 lbf ft) –...
  • Page 185 TECHNICAL DATA Screw, handlebar stub 8 Nm (5.9 lbf ft) Loctite ® 243™ – Screw, handlebar weight 8 Nm (5.9 lbf ft) – Screw, license plate holder on license 7 Nm (5.2 lbf ft) plate bracket Screw, magnetic holder on side stand 5 Nm (3.7 lbf ft) Loctite ®...
  • Page 186 TECHNICAL DATA – Screw, fuel tank attachment, rear, on 17 Nm (12.5 lbf ft) frame – Screw, horn 9 Nm (6.6 lbf ft) – Screw, main silencer 18 Nm (13.3 lbf ft) Screw, passenger footrest bracket 20 Nm (14.8 lbf ft) Loctite ®...
  • Page 187 TECHNICAL DATA – Swingarm bearing adjusting ring M22x1 Tighten and ensure that there is no play – Nut, steering head M30x1 55 Nm (40.6 lbf ft) 2. Loosen (counterclockwise) 2 turns 5 Nm (3.7 lbf ft)

  • Page 188: Substances

    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 189 SUBSTANCES Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants. Recommended supplier Motorex ® – COOLANT M3.0 Engine oil (SAE 15W/50) Standard/classification – JASO T903 MA ( p. 191) – SAE ( p. 191) (SAE 15W/50) Guideline –...
  • Page 190 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 191: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
  • Page 192 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 193: Standards

    STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifica- tion.

  • Page 194: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces On-board diagnosis Vehicle system that monitors emission- and safety-related values...

  • Page 195: List Of Abbreviations

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

  • Page 196: Changing The Engine Oil And Oil Filter, Cleaning

    LIST OF SYMBOLS 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system (optional). 29.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.

  • Page 197: Index

    INDEX INDEX Brake linings front brake, checking ......109 ABS ........104 rear brake, checking .
  • Page 198 INDEX coolant temperature indicator ..... 47 Emergency OFF switch ......25 display .
  • Page 199 INDEX removing ........84 Horn button ........23 Front spoiler installing .
  • Page 200 INDEX Rear wheel installing ........121 Oil filter removing .
  • Page 201 INDEX Spare parts ........14 Tool set .
  • Page 202 *3213560en* 3213560en 01/2017 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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