KTM 990 SUPER DUKE R EU Owner's Manual
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KTM 990 SUPER DUKE R EU Owner's Manual

2013
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2013
OWNER'S MANUAL
990 Super Duke R EU
990 Super Duke R AUS/UK
990 Super Duke R FR
Art. no. 3211960en

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Summary of Contents for KTM 990 SUPER DUKE R EU

  • Page 1 2013 OWNER'S MANUAL 990 Super Duke R EU 990 Super Duke R AUS/UK 990 Super Duke R FR Art. no. 3211960en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 DEAR KTM CUSTOMER 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. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Shock absorber part number ....... 22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 CONTROLS..............23 Symbols used ............7 Clutch lever............23 Formats used............7 Hand brake lever..........23 SAFETY ADVICE.............. 8 Throttle grip ............24 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS 6.11.17 Coolant temperature indicator ......37 10 TUNING THE CHASSIS ..........64 6.12 Opening the filler cap......... 37 10.1 Fork/shock absorber ........... 64 6.13 Closing the filler cap .......... 39 10.2 Adjusting the compression damping of the fork..64 6.14 Seat lock............
  • Page 7 TABLE OF CONTENTS 11.8 Removing the front spoiler ........81 13.2 Installing the front wheel ......104 11.9 Installing the front spoiler........81 13.3 Removing the rear wheel ......106 11.10 Removing the seat ..........82 13.4 Installing the rear wheel ......
  • Page 8 TABLE OF CONTENTS 16 TUNING THE ENGINE..........144 22.4 Chassis ............177 16.1 Checking the play in the throttle cable ....144 22.5 Electrical system..........179 22.6 tires..............180 16.2 Adjusting the play in the throttle cable ..145 22.7 Fork..............

  • 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: Safety Advice

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

  • Page 11: Degrees Of Risk And Symbols

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

  • Page 12: Safe Operation

    The vehicle should only be used by trained persons. 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 13: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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.

  • Page 14: 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 15: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 16: Figures

    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 side (example) L00403-10...
  • Page 19 VIEW OF VEHICLE Function buttons ( p. 28) Indicator lamps ( p. 29) Clutch lever ( p. 23) Filler cap Seat lock ( p. 40) Engine number ( p. 21) Side stand ( p. 44) Shift lever ( p. 43) Shock absorber, spring preload setting Compression damping of the shock absorber ( p.

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

    VIEW OF VEHICLE View of vehicle, rear right side (example) L00402-10...
  • Page 21 VIEW OF VEHICLE Light switch ( p. 25) Headlight flasher switch ( p. 25) Turn signal switch ( p. 26) Horn button ( p. 24) Emergency OFF switch ( p. 26) Electric starter button ( p. 27) Throttle grip ( p.

  • Page 22: Serial Numbers

    SERIAL NUMBERS Chassis number Chassis number is embossed in the steering head at the right. L00400-10 Type label Type label is located on the upper frame tube on the right. L00401-10...

  • Page 23: Key Number

    SERIAL NUMBERS Key number 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. 100179-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. L00404-10...

  • Page 24: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. L00405-10 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

  • Page 25: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B00157-10 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. B00158-10...

  • Page 26: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. 101182-10 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in basic position pressed – The horn is operated in this position. •...

  • Page 27: Light Switch

    CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The 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 high beam and tail light are switched on.

  • Page 28: 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 Left turn signal on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use. Right turn signal on –...

  • Page 29: 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 – The electric starter is actuated in this position. • Electric starter button 700552-11 6.10 Ignition/steering lock...

  • Page 30: Combination Instrument

    CONTROLS 6.11 Combination instrument 6.11.1 Overview The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. Function buttons Tachometer Indicator lights Display 400972-10 6.11.2 Function buttons You can change the display mode with the MODE button Possible display modes are the distance traveled (ODO), trip master 1 (TRIP 1), trip mas- ter 2 (TRIP 2) and the ambient temperature.

  • Page 31: Tachometer

    CONTROLS 6.11.3 Tachometer The tachometer shows the engine speed in revolutions per minute. The red marking shows the excess speed range of the engine. 400974-10 6.11.4 Indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle.

  • Page 32: Display

    CONTROLS The oil pressure warning lamp lights up red – The oil pressure is too low. FI warning lamp (MIL) lights up/flashes yellow – The OBD (on-board diagno- sis) has detected an emission- or safety-critical error. The battery warning lamp lights up red – The voltage in the vehicle system is too low.

  • Page 33: Speed Display

    CONTROLS 6.11.6 Speed display The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 6.11.7 Setting kilometers or miles Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary.

  • Page 34: Time

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.

  • Page 35: 6.11.10 Odo Display

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –...

  • Page 36: Setting/Resetting Display Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 400840-01 6.11.12 Setting/resetting display TRIP 2 Info...

  • Page 37: 6.11.13 Trip F Display

    CONTROLS 6.11.13 TRIP F display If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 400842-01 6.11.14 Ambient temperature indicator The ambient temperature...

  • Page 38: 6.11.16 Warning Of Icy Roads

    CONTROLS – Switch on the ignition by turning the ignition key to the ON position. – Press the MODE button repeatedly until the ambient temperature is active. – Keep the MODE button pressed until the display mode changes from °C to °F or from °F to °C.

  • Page 39: 6.11.17 Coolant Temperature Indicator

    CONTROLS 6.11.17 Coolant temperature indicator The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up. Possible states Engine cold –...
  • Page 40 CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Lift the cover of the filler cap and insert the ignition key in the lock. Note Danger of damage Ignition key breakage.

  • Page 41: Closing The Filler Cap

    CONTROLS 6.13 Closing the filler cap Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – When closing the filler cap, ensure that it is closed correctly. Change cloth- ing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.

  • Page 42: Seat Lock

    CONTROLS 6.14 Seat lock Seat lock is located at the rear of the seat. It can be locked with the ignition key. L00408-10 6.15 Baggage lugs Baggage lugs are located on the underside of the seat. Info When the seat is mounted, the lugs are accessible if they are turned outward. No more than one small piece of luggage with the specified weight may be attached to the turned-out baggage lugs.

  • Page 43: Tool Set

    CONTROLS 6.16 Tool set The tool set is located in the storage compartment under the seat. L00410-10 6.17 Supporting strap Supporting strap is mounted on the seat. The supporting strap is provided for the passenger to hold on to. L00409-10...

  • Page 44: Helmet Lock

    CONTROLS 6.18 Helmet lock Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle. – Do not use the helmet lock for holding a helmet or other objects during the jour- ney.

  • Page 45: Shift Lever

    CONTROLS 6.20 Shift lever Shift lever is mounted on the left side of the engine. L00414-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gear. L00415-10...

  • Page 46: Foot Brake Lever

    CONTROLS 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. L00419-10 6.22 Side stand The side stand is located on the left side of the vehicle. The side stand is used to park the motorcycle.

  • Page 47: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 48: Running In The Engine

    PREPARING FOR USE – 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 record at vehicle handover. – Before your first trip, read the entire operating instructions carefully.
  • Page 49 PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. – Mount and secure suitcase and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. –...
  • Page 50 PREPARING FOR USE – If you are carrying baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri- bution between the front and rear wheels. – Do not exceed the maximum permissible total weight and the axle loads. Guideline Maximum permissible total weight 387 kg (853 lb.)

  • Page 51: Riding Instructions

    RIDING INSTRUCTIONS 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. – Check the engine oil level.

  • Page 52: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 53: Starting Off

    RIDING INSTRUCTIONS – Press the emergency OFF switch into the position – Switch on the ignition by turning the ignition key to the ON position. After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 54: Shifting, Riding

    RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –...
  • Page 55 RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
  • Page 56 If you continue riding while the coolant temperature warning lamp is lit, the engine may be damaged. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 57: Braking

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.

  • Page 58: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.
  • Page 59 RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.

  • Page 60: Transport

    RIDING INSTRUCTIONS Transport Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances.

  • Page 61: 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. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 62 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 37) – Fill the fuel tank with fuel no higher than the lower edge of the filler neck. Total fuel tank 18.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 63: Service Schedule

    Check that the electrical equipment is functioning properly. • • • • • • • • Read out the trouble code memory using the KTM diagnostics tool. • • • Check the measured service values with the KTM diagnostics tool. • • • •...
  • Page 64 • • Change the air filter. Clean the air filter box. • • • Check the fuel pressure. Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics • • • tool. • • •...
  • Page 65 • • • • • • Read out the fault memory after a test ride using the KTM diagnostics tool. • • • • Make the service entries in the KTM DEALER.NET and service record. K10N: Once after 1,000 km (621.4 mi)

  • Page 66: Tuning The Chassis

    TUNING THE CHASSIS 10.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to your rid- ing 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

    TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping L00418-10...

  • Page 68: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping L00417-10...
  • Page 69 TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of turns according to the fork type. Guideline Spring preload - Preload Adjuster L00417-11...

  • Page 70: Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 71: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 72: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 73: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 12 clicks Standard 10 clicks Sport 8 clicks L00449-10 Info Turn clockwise to increase damping;...
  • Page 74 TUNING THE CHASSIS Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are fully relieved of weight. Main work – Loosen locking ring – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) –...

  • Page 75: Handlebar Position

    TUNING THE CHASSIS 10.10 Handlebar position On the upper triple clamp are two holes a distance of apart. Hole distance 15 mm (0.59 in) The handlebar can be mounted in two different positions. In this way, the handlebar can be installed in the position most comfortable for the rider.

  • Page 76: Steering Damper

    TUNING THE CHASSIS Info Position the handlebar supports evenly on the left and right. – Position the handlebar. Info Ensure that the cables and lines are routed correctly. – Position the handlebar clamp. Mount and tighten the four screws and tighten evenly. Guideline Screw, handlebar clamp 20 Nm...

  • Page 77: Adjusting The Steering Damper

    TUNING THE CHASSIS 10.13 Adjusting the steering damper Info The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load. In contrast to other absorbing elements, the steering damper is adjusted with the absorbing element open. –...

  • Page 78: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the lifting bushings on the swingarm. –...

  • Page 79: Raising The Motorcycle With The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Preparatory work – Raise the motorcycle with the rear wheel stand.

  • Page 80: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.5 Bleeding the fork legs Preparatory work – Lean the motorcycle on the side stand. Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten the bleeder screws. Info Carry out this operation on both fork legs.

  • Page 81: Installing The Spoiler

    SERVICE WORK ON THE CHASSIS – Remove screws – Take off the spoiler. L00422-10 11.7 Installing the spoiler Info The operations are the same on the left and right sides.
  • Page 82 SERVICE WORK ON THE CHASSIS – Position the spoiler. – Mount and tighten screws Guideline Screw, spoiler 6 Nm (4.4 lbf ft) L00422-10...

  • Page 83: Removing The Front Spoiler

    SERVICE WORK ON THE CHASSIS 11.8 Removing the front spoiler – Remove screws with the washer. 0 0 0 1 – Loosen screws and remove the front spoiler from the front. B00245-10 11.9 Installing the front spoiler – Position the front spoiler. 0 0 0 1 –...

  • Page 84: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11.10 Removing the seat – Insert the ignition key in the seat lock and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards. L00408-10 11.11 Mounting the seat –...

  • Page 85: Mounting The Helmet Lock On The Vehicle

    SERVICE WORK ON THE CHASSIS 11.12 Mounting the helmet lock on the vehicle Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle. – Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before start- ing out.

  • Page 86: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11.14 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 87: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.15 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

  • Page 88: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.16 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.
  • Page 89 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning the adjusting screws on the left and right. Guideline Chain tension 7 mm (0.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjuster are in the same position in relation to reference marks .

  • Page 90: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS 11.17 Checking the chain, rear sprocket, engine sprocket and chain guide – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the power set. Info The rear sprocket, engine sprocket and chain should always be changed together.
  • Page 91 SERVICE WORK ON THE CHASSIS – Shift the transmission to neutral. – Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 92 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If there is no gap between the chain and the upper edge of the screw: – Change the chain sliding guard. – Check the chain sliding guard for tightness. »...

  • Page 93: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11.18 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited.
  • Page 94 SERVICE WORK ON THE CHASSIS – Check the fluid level. The fluid level must be between the MIN and MAX markings. » If the coolant level does not meet specifications: – Remove the screw cap with the membrane. – Correct the fluid level of the hydraulic clutch. Hydraulic fluid (15) ( p.

  • Page 95: Brake System

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the brake disc in several places to see if it conforms to measure-...

  • Page 96: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 97: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 98: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...
  • Page 99 BRAKE SYSTEM – Check all brake linings on both brake calipers to ensure they have minimum thick- ness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. –...

  • Page 100: Adjusting The Basic Position Of The Foot Brake Lever

    Lock nut – Position bellows L00444-10 12.7 Checking the rear brake disc Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)

  • Page 101: Checking The Rear Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 102: Adding Rear Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 103: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. L00428-10 12.10 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
  • Page 104 BRAKE SYSTEM Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly. –...

  • Page 105: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Remove the frame slider. – Raise the motorcycle with the rear wheel stand. ( p. 76) – Raise the motorcycle with the front wheel stand. ( p. 77) Main work –...

  • Page 106: Installing The Front Wheel

    WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work –...
  • Page 107 WHEELS, TIRES – Position the brake calipers and check that the brake linings are seated correctly. – Mount screws on both brake calipers but do not tighten yet. – Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point.

  • Page 108: Removing The Rear Wheel

    WHEELS, TIRES 13.3 Removing the rear wheel Preparatory work – Remove the frame slider. – Raise the motorcycle with the rear wheel stand. ( p. 76) Main work – Remove nut . Remove chain adjuster – Pull out wheel spindle to the point where the chain adjuster is no longer in contact with the adjusting screw.

  • Page 109: Installing The Rear Wheel

    WHEELS, TIRES 13.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake.
  • Page 110 WHEELS, TIRES – Engage the counter bearing of the brake caliper support and swingarm. Carefully lift the rear wheel into the swingarm and engage the brake disc. Lay the chain on the rear sprocket and mount the wheel spindle. – Mount chain adjuster and nut Info...

  • Page 111: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES 13.5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 5 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 will be damaged. Preparatory work –...

  • Page 112: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 113: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to 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 114 WHEELS, TIRES – Remove the protection cap. – Check the tire air pressure when the tires are cold. Tire air pressure, solo Front 2.4 bar (35 psi) Rear 2.4 bar (35 psi) Tire air pressure with passenger/full payload Front 2.4 bar (35 psi) 400695-01 Rear 2.6 bar (38 psi)

  • Page 115: Electrical System

    ELECTRICAL SYSTEM 14.1 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 goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 116 ELECTRICAL SYSTEM Main work – Remove the cable binder. – Detach the connector from the start relay. – Push the wiring harness to the side. – Remove screws – Fold cover down. B00191-10 – Disconnect negative cable of the battery. –...

  • Page 117: Installing The Battery

    ELECTRICAL SYSTEM 14.2 Installing the battery Main work – Position the battery in the battery compartment. – Connect positive cable – Connect negative cable B00192-11 – Fold cover – Mount and tighten screws – Attach the connector to the start relay. –...

  • Page 118: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 119 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
  • Page 120 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 rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid Charge the battery at no more than 10% of the capacity specified on battery...

  • Page 121: Changing The Main Fuse

    ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. The main fuse is located next to the battery under the front spoiler. Preparatory work –...
  • Page 122 ELECTRICAL SYSTEM Main work – Detach the connector and protection cap – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p.

  • Page 123: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 14.5 Changing the fuses of individual power consumers Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work –...
  • Page 124 ELECTRICAL SYSTEM – Check the fuses. Info A defective fuse can be identified by the burned-out fuse wire – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition Fuse 2 - 15 A - high beam, low beam, parking light, tail light, license plate lamp B00196-10 Fuse 3 - 10 A - horn, brake light, turn signal Fuse 4 - 10 A - radiator fan...

  • Page 125: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 82) 14.6 Changing the low beam bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 126 ELECTRICAL SYSTEM – Cover the fender with a cloth. – Swing the headlight mask forward. L00430-10 – Remove protection cap – Disconnect plug-in connector L00446-10 – Detach spring bar – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Low beam (H7/socket PX26d) ( p.

  • Page 127: Changing The High Beam Bulb

    ELECTRICAL SYSTEM – Position the spring bar. – Connect plug-in connection – Mount protection cap L00446-10 – Position the headlight mask. Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Check that the lighting is functioning properly. L00429-10 14.7 Changing the high beam bulb...
  • Page 128 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. Main work – Remove screws L00429-10 – Cover the fender with a cloth. – Swing the headlight mask forward. L00430-10...
  • Page 129 ELECTRICAL SYSTEM – Remove protection cap – Disconnect plug-in connector L00447-10 – Detach spring bar – Remove headlight bulb – Position the new headlight bulb in the headlight housing. High beam (H3/socket PX22s) ( p. 179) Info Insert the headlight bulb so that the catches latch into the recesses. –...

  • Page 130: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Position the headlight mask. Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Check that the lighting is functioning properly. L00429-10 14.8 Changing the parking light bulb Note Damage to reflector Reduced brightness. –...

  • Page 131: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Push the headlight mask spoiler slightly to the side. – Pull out lamp socket – Remove bulb – Position a new light bulb in the holder. Parking light (W5W/socket W2.1x9.5d) ( p. 179) – Carefully position the socket with the bulb into the holder in the headlight. L00434-10 –...

  • Page 132: Changing The Brake Light Bulb

    ELECTRICAL SYSTEM – Remove the screw on the rear of the turn signal housing. – Carefully remove diffuser – Press bulb carefully into the socket, turn it counterclockwise by about 30°, and pull it out of the socket. – Press the new bulb carefully into the socket and turn it clockwise until it stops. Turn signal (RY10W/socket BAU15s) ( p.
  • Page 133 ELECTRICAL SYSTEM Main work – Turn bulb socket counterclockwise all the way and take it out of the tail light. L00432-10 – Push bulb carefully into the socket, turn it counterclockwise and pull it out of the socket. – Press the new bulb carefully into the socket and turn it clockwise until it stops. Brake light (PR21W/socket BAW15s) ( p.

  • Page 134: Changing The Tail Light Bulbs

    ELECTRICAL SYSTEM 14.11 Changing the tail light bulbs Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 135: Changing The License Plate Lamp

    ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 82) – Check that the tail light bulbs are functioning properly. 14.12 Changing the license plate lamp Main work – Remove screws B00212-10 – Carefully pull socket out of the holder. –...

  • Page 136: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Position the license plate holder. – Mount and tighten screws B00212-10 Finishing work – Check that the license plate lamp is functioning properly. 14.13 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the level of the center of the headlight.

  • Page 137: Adjusting The Headlight Range

    ELECTRICAL SYSTEM The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate 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 138: Cooling System

    COOLING SYSTEM 15.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radia- tor cap. This permits the specified coolant temperature without causing any malfunctions. 125 °C (257 °F) L00438-10 Cooling takes place by means of the air stream and a radiator fan, which is controlled by a...
  • Page 139 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 140 COOLING SYSTEM Alternative 1 Coolant ( p. 186) Alternative 2 Coolant (mixed ready to use) ( p. 186) » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! –...

  • Page 141: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM 15.3 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 remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 142: Draining The Coolant

    COOLING SYSTEM – Add coolant to the max marking. Alternative 1 Coolant ( p. 186) Alternative 2 Coolant (mixed ready to use) ( p. 186) – Mount the cap of the compensating tank. – Install the spoiler. ( p. 79) »...

  • Page 143: Filling/Bleeding The Cooling System

    COOLING SYSTEM – Remove radiator cap B00221-10 – Place a suitable container under the engine. – Remove screw – Tilt the vehicle slightly to the right. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft)
  • Page 144 COOLING SYSTEM Preparatory work – Remove the spoiler. ( p. 78) Main work – Ensure that the drain plug on the water pump cover is tightened. – Remove bleeder screw B00223-10 – Position the vehicle as shown and secure it against rolling. Height difference must be reached.
  • Page 145 COOLING SYSTEM – Remove the radiator cap and pour in coolant until it emerges without bubbles at the vent hole, and then immediately mount and tighten the bleeder screw Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) Alternative 1 Coolant ( p.

  • Page 146: Tuning The Engine

    TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 147: Adjusting The Play In The Throttle Cable

    16.2 Adjusting the play in the throttle cable – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the basic position. – Push back sleeve – Loosen lock nut –...

  • Page 148: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16.4 Adjusting the basic position of the shift lever – Release nuts and turn shift rod until the shift lever is in the desired position. Guideline Distance < 70 mm (< 2.76 in) Info Distance must not be exceeded! The range of adjustment is limited.

  • Page 149: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Preparatory work Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 150: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil and filter, clean the oil screens. p. 148) – Fill up with engine oil. p. 152) B00119-01 17.3 Draining the engine oil and filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
  • Page 151 SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring. – Fully drain the engine oil out of the engine. B00225-10 – Remove screws and cover –...
  • Page 152 SERVICE WORK ON THE ENGINE – Pull oil sieve out of the oil tank. B00228-10 – Remove screws . Take off oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) –...
  • Page 153 SERVICE WORK ON THE ENGINE – Check seal ring of the oil sieve for damage and correct seating. – Insert oil sieve into the oil tank. B00231-10 – Position oil line . Mount and tighten screws Guideline Remaining engine screws 10 Nm (7.4 lbf ft) –...

  • Page 154: Filling Up With Engine Oil

    SERVICE WORK ON THE ENGINE – Slide oil sieve into the engine case with the TOP marking facing up. – Check the form ring in cover for damage and correct seating. – Position the cover. Mount and tighten the screws. Guideline Screw, clutch cover 10 Nm (7.4 lbf ft)
  • Page 155 SERVICE WORK ON THE ENGINE Main work – The oil must be added in two steps. Engine oil 3.0 l (3.2 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 187) External Engine oil (SAE temperature: 5W/40) ( p.

  • Page 156: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Park the motorcycle on a horizontal surface in a vertical position (not on the side stand). – Remove the plug. – Add engine oil to the max marking of oil rising pipe Engine oil (2nd 0.50 l (0.53 qt.) External Engine oil...
  • Page 157 SERVICE WORK ON THE ENGINE Main work – Remove screw plug – Add engine oil to the max marking of oil rising pipe Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p. 187) Condition External temperature: <...

  • Page 158: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 159 CLEANING, CARE Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.

  • Page 160: Checks And Maintenance Measures For Winter Operation

    CLEANING, CARE – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 191) – Lubricate the ignition/steering lock. Universal oil spray ( p.
  • Page 161 CLEANING, CARE – Clean the chain. ( p. 84)

  • Page 162: Storage

    Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should do this during the storage period (less overload of the authorized KTM workshop). In this way, you can avoid long waiting times at the authorized KTM workshop at the start of the new season.
  • Page 163 – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 76) – Raise the motorcycle with the front wheel stand. ( p.

  • Page 164: Preparing For Use After Storage

    STORAGE 19.2 Preparing for use after storage – Take the motorcycle off of the front wheel stand. ( p. 77) – Take the motorcycle off of the rear wheel stand. ( p. 76) – Recharge the battery. p. 116) – Install the battery.

  • Page 165: Troubleshooting

    Coupling of fuel hose connection not Reconnect coupling of fuel hose connection. connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter very dirty Change the air filter.
  • Page 166 Fill/bleed the cooling system. p. 141) – FI warning lamp (MIL) lights up/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during a trip Lack of fuel Refuel. ( p.
  • Page 167 TROUBLESHOOTING Faults Possible cause Action – Battery discharged Ignition not switched off when vehicle Recharge the battery. p. 116) was parked – Battery is not charged by the alternator Check the charging voltage. – Combination instrument shows nothing Fuse 6 blown Change the fuses of individual power consumers.

  • Page 168: Blink Code

    BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Circuit ignition pulse generator - circuit fault Blink code of FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle valve sensor circuit A - input signal too low Throttle valve sensor circuit A - input signal too high...
  • Page 169 BLINK CODE Blink code of FI warning lamp (MIL) 12 FI warning lamp (MIL) flashes 1x long, 2x short Error level condition Coolant temperature sensor - input signal too low Coolant temperature sensor - input signal too high Blink code of FI warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Error level condition...
  • Page 170 BLINK CODE Blink code of FI warning lamp (MIL) 18 FI warning lamp (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Blink code of FI warning lamp (MIL) 24 FI warning lamp (MIL) flashes 2x long, 4x short Error level condition Power supply - circuit fault Blink code of FI warning...
  • Page 171 BLINK CODE Blink code of FI warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code of FI warning lamp (MIL) 38 FI warning lamp (MIL) flashes 3x long, 8x short Error level condition Ignition coil 1, cylinder 2 - circuit fault Blink code of FI warning...
  • Page 172 BLINK CODE Blink code of FI warning lamp (MIL) 49 FI warning lamp (MIL) flashes 4x long, 9x short Error level condition Motor drive circuit A - circuit fault Blink code of FI warning lamp (MIL) 50 FI warning lamp (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Blink code of FI warning...
  • Page 173 BLINK CODE Blink code of FI warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition CAN bus communication error...

  • Page 174: Technical Data

    TECHNICAL DATA 22.1 Engine Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 999 cm³ (60.96 cu in) Stroke 62.4 mm (2.457 in) Bore 101 mm (3.98 in) Compression ratio 11.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter Exhaust 33 mm (1.3 in) Intake...

  • Page 175: Engine Tightening Torques

    TECHNICAL DATA 3rd gear 20:30 4th gear 21:27 5th gear 23:26 6th gear 25:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug NGK LKAR8BI-9 Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump...
  • Page 176 TECHNICAL DATA ® Plug, vacuum connection 5 Nm (3.7 lbf ft) Loctite 243™ – Remaining engine screws 10 Nm (7.4 lbf ft) – Screw in alternator cover 10 Nm (7.4 lbf ft) ® Screw, bearing bolt in alternator cover 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 177 TECHNICAL DATA – Screw, camshaft bearing support Step 1 10 Nm (7.4 lbf ft) Step 2 18 Nm (13.3 lbf ft) – Screw, clutch cover 15 Nm (11.1 lbf ft) ® Screw, cylinder head Step 1 Loctite 243™ 18 Nm (13.3 lbf ft) Step 2 23 Nm (17 lbf ft) ®...

  • Page 178: Capacities

    TECHNICAL DATA – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 60° – Spark plug M12x1.25 18 Nm (13.3 lbf ft) – Engine coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –...

  • Page 179: Coolant

    TECHNICAL DATA Engine oil 3.0 l (3.2 qt.) External temperature: < 0 °C Engine oil (SAE 5W/40) (< 32 °F) p. 187) 22.3.2 Coolant Coolant 2.10 l (2.22 qt.) Coolant ( p. 186) Coolant (mixed ready to use) ( p. 186) 22.3.3 Fuel Total fuel tank capacity, approx.
  • Page 180 TECHNICAL DATA Front 320 mm (12.6 in) Rear 240 mm (9.45 in) Brake discs - wear limit Front 4 mm (0.16 in) Brake disc - wear limit Rear 4.5 mm (0.177 in) Tire air pressure, solo Front 2.4 bar (35 psi) Rear 2.4 bar (35 psi) Tire air pressure with passenger/full payload...

  • Page 181: Electrical System

    TECHNICAL DATA 22.5 Electrical system Battery YTZ14S Battery voltage: 12 V Nominal capacity: 11.2 Ah maintenance-free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 58011109130 30 A Low beam H7/socket PX26d 12 V 55 W High beam H3/socket PX22s 12 V 55 W Parking light...

  • Page 182: Tires

    Rear tires 120/70 ZR 17 M/C 58W TL 180/55 ZR 17 M/C 73W TL Metzeler Sportec M5 Interact Metzeler Sportec M5 Interact Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.7J.31 Fork WP Suspension Up Side Down 4860 ROMA PA...

  • Page 183: Shock Absorber

    TECHNICAL DATA Soft 9 N/mm (51 lb/in) Medium (standard) 9.5 N/mm (54.2 lb/in) Hard 10 N/mm (57 lb/in) Fork length 757 mm (29.8 in) Air chamber length 100±20 mm (3.94±0.79 in) Fork oil per fork leg 517 ml (17.48 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p.

  • Page 184: Chassis Tightening Torques

    TECHNICAL DATA Standard 6 mm (0.24 in) Sport 6 mm (0.24 in) Spring rate Soft 160 N/mm (914 lb/in) Medium (standard) 170 N/mm (971 lb/in) Hard 180 N/mm (1,028 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag 17 mm (0.67 in) Fitted length...

  • Page 185: Nm (18.4 Lbf Ft)

    TECHNICAL DATA ® Screw, front spoiler 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, fuel pump 6 Nm (4.4 lbf ft) – Screw, fuel tank holder 6 Nm (4.4 lbf ft) ® Screw, heel protector 2 Nm (1.5 lbf ft) Loctite 243™...

  • Page 186: Nm (7.4 Lbf Ft) Loctite

    TECHNICAL DATA ® Screw, rear footrest bracket 25 Nm (18.4 lbf ft) Loctite 243™ ® Screw, shift lever 25 Nm (18.4 lbf ft) Loctite 243™ ® Screw, shift shaft relay lever 25 Nm (18.4 lbf ft) Loctite 243™ ® Screw, spring holder on side stand 25 Nm (18.4 lbf ft) Loctite 243™...

  • Page 187: Nm (95.9 Lbf Ft)

    TECHNICAL DATA – Lambda sensor M18x1.5 45 Nm (33.2 lbf ft) – Nut, seat lock M19x1 8 Nm (5.9 lbf ft) Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased – Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) –...

  • Page 188: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ing properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 189 SAE ( p. 193) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex ® products. Fully synthetic engine oil Supplier Motorex ®...
  • Page 190 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® –...
  • Page 191 SUBSTANCES 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. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 192: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 193 AUXILIARY SUBSTANCES High-luster polish for paint Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Polish Long-life grease Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex ®...
  • Page 194 AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...

  • Page 195: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 196: Index

    INDEX INDEX Brake light bulb changing ........130 Accessories .
  • Page 197 INDEX Clutch lever ........basic position, adjusting ......91 Electric starter button .
  • Page 198 INDEX rebound, adjusting ......65 spring preload, adjusting ......66 Ignition lock .
  • Page 199 INDEX Oil screens Refueling cleaning ........148 fuel .
  • Page 200 INDEX Spoiler Tire condition installing ........79 checking .
  • Page 201 *3211960en* 3211960en 11/2012 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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