KTM 990 SUPERMOTO T EU Owner's Manual
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KTM 990 SUPERMOTO T EU Owner's Manual

2013
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2013
OWNER'S MANUAL
990 Supermoto T EU
990 Supermoto T AUS/UK
990 Supermoto T FR
Art. no. 3211957en

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Summary of Contents for KTM 990 SUPERMOTO T EU

  • Page 1 2013 OWNER'S MANUAL 990 Supermoto T EU 990 Supermoto T AUS/UK 990 Supermoto T FR Art. no. 3211957en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, as well as printing 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 6.12.16 Warning of icy roads........37 Refueling ............60 6.12.17 Coolant temperature indicator ......38 SERVICE SCHEDULE ............ 62 6.13 Hazard warning flasher switch/hazard warning Service schedule..........62 flasher .............. 38 10 TUNING THE CHASSIS ..........65 6.14 Socket for electrical accessories ......
  • Page 7 TABLE OF CONTENTS 11.9 Positioning the fuel tank........79 13 WHEELS, TIRES ............106 11.10 Mounting the helmet lock on the vehicle ....80 13.1 Removing the front wheel ......106 11.11 Removing the mask spoiler ......... 81 13.2 Installing the front wheel ......
  • Page 8 TABLE OF CONTENTS 15.3 Checking the coolant level in the compensating 23 TECHNICAL DATA............188 tank..............152 23.1 Engine ............188 15.4 Draining the coolant ........153 23.2 Engine tightening torques ......... 189 15.5 Filling/bleeding the cooling system ....154 23.3 Capacities ............

  • 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 but not for use on race courses or offroad. 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) L00600-10...
  • Page 19 VIEW OF VEHICLE Function buttons ( p. 29) indicator lamps ( p. 30) Clutch lever ( p. 23) Handrails ( p. 42) Level viewer, engine oil Shift lever ( p. 44) Engine number ( p. 21) 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) L00601-10...
  • Page 21 VIEW OF VEHICLE Seat lock ( p. 41) Light switch ( p. 25) Headlight flasher switch ( p. 25) Turn signal switch ( p. 26) Horn button ( p. 24) Filler cap Emergency OFF switch ( p. 26) Electric starter button ( p.

  • Page 22: Serial Numbers

    SERIAL NUMBERS Chassis number Chassis number is embossed in the steering head at the right. L00604-10 Type label Type label is located on the upper frame tube on the right. L00603-10...

  • Page 23: Key Number

    SERIAL NUMBERS Key number The Code 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. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.

  • Page 24: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. B00606-10 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. B00608-10 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. B00609-10...

  • Page 26: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. B00655-10 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 B00657-11 6.10 Ignition/steering lock...

  • Page 30: Immobilizer

    The second black ignition key is activated when the vehicle is shipped. Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop, but they need to be activated for use. 6.12 Combination instrument 6.12.1...

  • Page 31: Function Buttons

    CONTROLS 6.12.2 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. Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- tion (TRIP 2) to 0.0.

  • Page 32: Indicator Lamps

    CONTROLS 6.12.4 indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up green – The transmission is shifted to idle.

  • Page 33: Display

    CONTROLS 6.12.5 Display When you switch on the ignition, all display segments light up for one second as a function check. 400892-01 LEnGth Following the display function check, the LEnGth wheel circumference is shown for one sec- ond. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series pro- duction tire.

  • Page 34: Speed Display

    CONTROLS 6.12.6 Speed display The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 6.12.7 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 35: 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 36: 6.12.10 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 37: 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 6.12.12 Setting/resetting display TRIP 2 Info...

  • Page 38: 6.12.13 Trip F Display

    CONTROLS 6.12.13 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 6.12.14 Ambient temperature indicator The ambient temperature...

  • Page 39: 6.12.16 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 40: 6.12.17 Coolant Temperature Indicator

    CONTROLS 6.12.17 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 41: Socket For Electrical Accessories

    CONTROLS 6.14 Socket for electrical accessories Socket for electrical accessories is fitted next to the ignition/steering wheel lock on the left. It is connected to the battery without an additional switch. Socket for electrical accessories Voltage 12 V Maximum current con- 10 A sumption B00614-10...

  • Page 42: Closing The Filler Cap

    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. Note Danger of damage Ignition key breakage.

  • Page 43: Seat Lock

    CONTROLS 6.17 Seat lock Seat lock is located at the rear under the tail light. It can be locked with the ignition key. 600922-10 6.18 Tool set The tool set is located in the storage compartment under the seat. B00612-10...

  • Page 44: Handrails

    CONTROLS 6.19 Handrails The handrails are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the handrails during the trip. 600923-10 6.20 Helmet lock Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle.

  • Page 45: Luggage Rack Plate

    CONTROLS 6.21 Luggage rack plate The luggage rack plate is located behind the seat. The base plate of a luggage system can be mounted on the luggage rack plate (optional). The luggage rack plate may not be loaded with more than the specified weight. Maximum permissible load of 8 kg (18 lb.) luggage rack plate...

  • Page 46: Shift Lever

    CONTROLS 6.23 Shift lever Shift lever is mounted on the left side of the engine. L00610-11 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gear. L00610-10...

  • Page 47: Foot Brake Lever

    CONTROLS 6.24 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is activated using the foot brake lever. L00613-10 6.25 Side stand The side stand is located on the left side of the vehicle. The side stand is used to park the motorcycle.

  • Page 48: 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 49: 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 50 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 51 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 400 kg (882 lb.)

  • Page 52: 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 53: 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 54 Take the weight off the side stand and swing it upwards with your foot as far as it will Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous.

  • Page 55: Starting Off

    RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 56 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 57 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 58: 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 59 RIDING INSTRUCTIONS 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. Warning Danger of accidents Greater stopping distance due to ABS.

  • Page 60: Stopping, Parking

    RIDING INSTRUCTIONS – On long downhill stretches, use the braking effect of the engine. Do this by changing down two gears, but do not race the engine. You will require less braking force and the brakes will not overheat. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons.

  • Page 61: Transport

    RIDING INSTRUCTIONS – Apply the brakes. – Shift the transmission to neutral. – Switch off the ignition by turning the ignition key to the OFF position. Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery is soon discharged.

  • Page 62: Refueling

    Material damage Premature clogging of the fuel filter. – 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.)
  • Page 63 RIDING INSTRUCTIONS – Only refuel with clean fuel that meets the specified standards. 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. –...

  • Page 64: 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 65 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 66 • • • • • • 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 67: 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 68: 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 B00617-10...

  • Page 69: 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 C00379-10...
  • Page 70 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 C00379-11...

  • Page 71: 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 72: 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 73: 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 74: 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 20 clicks Standard 15 clicks Sport 10 clicks C00377-10 Full payload 10 clicks...
  • Page 75 TUNING THE CHASSIS – Remove screw and take off the brake line guide. Info The brake line guide must always be removed to avoid damage to the brake line. C00136-10 – Push the brake lines carefully to the side. – Turn the Preload Adjuster counterclockwise all the way.
  • Page 76 TUNING THE CHASSIS – Position the brake line guide and brake line. Info Watch out for the holding lug of the brake line guide. – Mount and tighten screw Guideline Screw, brake line holder EJOT PT K60x20 2 Nm (1.5 lbf ft) C00136-10...

  • Page 77: 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 78: 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 79: 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 80: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11.7 Mounting the seat – Position front recesses of the seat on the oval head screws of the fuel tank, lower the rear and simultaneously push it forward. Both lugs must hook into the frame and locking bolt must be inserted into the lock housing.

  • Page 81: Positioning The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screw on both sides. Info The fuel hoses do not need to be disconnected. – Carefully push the fuel tank back. C00368-11 11.9 Positioning the fuel tank Main work – Carefully push the fuel tank forward. The fuel tank fixations must engage in the recesses.

  • Page 82: Mounting The Helmet Lock On The Vehicle

    SERVICE WORK ON THE CHASSIS – Position the spoilers on both sides. Mount and tighten screws Guideline Screw, spoiler 3.3 Nm (2.43 lbf ft) C00369-11 Finishing work – Install the mask spoiler. ( p. 83) – Mount the seat. ( p.

  • Page 83: Removing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS – Remove the seat. ( p. 77) – Position the steel cable from the tool set with one loop on the lug Steel cable (60012015000) – Guide the steel cable through the helmet opening. – Then position the free loop of the steel cable on the lug.
  • Page 84 SERVICE WORK ON THE CHASSIS – Remove screws – Remove the mask spoiler. C00366-10 – Remove screws – Remove the inside trim of the mask spoiler. – Repeat the operation on the opposite side. C00365-11...

  • Page 85: Installing The Mask Spoiler

    SERVICE WORK ON THE CHASSIS 11.12 Installing the mask spoiler – Position the inside trim of the mask spoiler. – Mount and tighten screws C00365-10 – Position the mask spoiler. – Mount and tighten screws C00367-11...

  • Page 86: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS – Mount and tighten screws – Repeat the operation on the opposite side. C00366-11 11.13 Checking the chain for dirt – Check the chain for coarse dirt accumulation. » If the chain is very dirty: –...
  • Page 87 SERVICE WORK ON THE CHASSIS 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 Environmental hazard Hazardous substances cause environmental damage.

  • Page 88: 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 89: 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 90 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 91: 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 92 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 93 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 94: 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 95 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »...

  • Page 96: Brakes

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling 0 0 1 straight ahead without the action of lateral forces.

  • Page 97: Adjusting The Basic Position Of The Hand Brake Lever

    Do not make any adjustments while riding! B00627-10 12.3 Checking the front brake discs 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 98: Checking The Front 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 99: Adding Front 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 100: Checking The Front Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 12.6 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.)

  • Page 101: Checking The Free Travel Of The Foot Brake Lever

    BRAKES 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 102: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKES – Move the foot brake lever back and forth between the end stop and the contact to the piston rod and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The piston rod should not move. »...

  • Page 103: Checking The Rear Brake Disc

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 104: Adding Rear 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.) – Stand the vehicle upright.
  • Page 105 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 106: Checking The Rear Brake Linings

    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.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...
  • Page 107 BRAKES – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »...

  • Page 108: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 75) – Raise the motorcycle with the front wheel stand. ( p. 76) Main work – Take the speed sensor cable out of the clamp. –...

  • Page 109: 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. –...
  • Page 110 WHEELS, TIRES – Slide the sleeve onto the wheel speed sensor and push them into the hole together. Mount and tighten screw Guideline Screw, wheel speed sensor 6 Nm Loctite ® 243™ (4.4 lbf ft) – Fasten the speed sensor cable in the bracket. –...

  • Page 111: Removing The Rear Wheel

    WHEELS, TIRES – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) B00686-10 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the rear wheel stand.
  • Page 112 WHEELS, TIRES Main work – Remove screw and pull wheel speed sensor out of the hole. – 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 113: Installing The Rear Wheel

    WHEELS, TIRES – Take the rear wheel carefully out of the swingarm without damaging the rim and/or brake disc. Info Do not operate the foot brake when the rear wheel is removed. 13.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...
  • Page 114 WHEELS, TIRES Long-life grease ( p. 207) – Clean the fixing locations on the brake caliper support and swingarm. – 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.

  • Page 115: 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 116: 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 117: 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 118 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 119: 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 120 ELECTRICAL SYSTEM Main work – Disconnect negative (minus) cable of the battery. B00637-10 – Remove positive terminal cover – Disconnect the positive (plus) cable of the battery. – Detach rubber band – Pull the battery up and out of the battery holder. B00638-10...

  • Page 121: Installing The Battery

    ELECTRICAL SYSTEM 14.2 Installing the battery Main work – Position the battery in the battery holder. Info The terminals of the battery must face in the direction of travel. – Attach rubber band – Reconnect the positive (plus) cable of the battery. –...

  • Page 122: 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 123 ELECTRICAL SYSTEM 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. 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 124: Changing The Main Fuse

    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 to no more than 10% of the capacity specified on battery...
  • Page 125 ELECTRICAL SYSTEM Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 77) Main work –...

  • Page 126: Changing The Abs Fuses

    ELECTRICAL SYSTEM 14.5 Changing the ABS fuses 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 Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box.

  • Page 127: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM To change the fuse of the ABS return pump: – Take off the protection cap and remove fuse – Insert the new fuse. Fuse (58011109130) – Mount the protection cap. B00639-11 Finishing work – Mount the seat. ( p.
  • Page 128 ELECTRICAL SYSTEM Main work – Open fuse box cover – Check the fuses. Info A faulty fuse can be identified by the burned-out fuse wire – Remove the faulty fuse. Guideline B00648-10 Fuse 1 - 10 A - ignition, fuel pump, hazard warning flasher Fuse 2 - 15 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 3 - 10 A - horn, brake light, turn signal Fuse 4 - 10 A - radiator fan...

  • Page 129: Changing The Headlight Bulb

    ELECTRICAL SYSTEM Insert a spare fuse so that it is available if needed. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 78) 14.7 Changing the headlight 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 130 ELECTRICAL SYSTEM – Disconnect connector – Remove protection cap B00673-10 – Detach retaining clamps – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Low beam/high beam (H4/socket P43t) ( p. 195) Info Insert the headlight bulb so that the catches latch into the recesses. –...

  • Page 131: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Mount the cover. – Check that the lighting is functioning properly. B00668-01 14.8 Changing the parking light 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 132 ELECTRICAL SYSTEM – Pull cable guide and the socket of the parking light carefully out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9.5d) ( p. 195) – Carefully position the socket with the bulb in the housing. –...

  • Page 133: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM 14.9 Changing the turn signal 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 134 ELECTRICAL SYSTEM Main work – Remove screws – Remove the grab handles. B00641-10 – Remove screws on the left and right heat protectors. – Remove the heat protectors. C00355-10...
  • Page 135 ELECTRICAL SYSTEM – Remove screws on the left and right rear side parts. – Remove screws – Remove the rear side parts. C00356-10 – Remove screws – Remove the rear top part. B00644-10...
  • Page 136 ELECTRICAL SYSTEM – Turn bulb socket counterclockwise all the way and take it out of the tail light. – Push the 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 137 ELECTRICAL SYSTEM – Position the rear side parts. – Mount and tighten screws on the left and right rear side parts. Guideline Screw, rear side part EJOT Altracs Initial screw con- 50x16 nection 3.3 Nm (2.43 lbf ft) Subsequent screw connection 2 Nm (1.5 lbf ft) –...

  • Page 138: Changing The Tail Light Bulbs

    ELECTRICAL SYSTEM – Position the grab handles. – Mount and tighten screws Guideline Screw, handrail 20 Nm (14.8 lbf ft) B00641-10 Finishing work – Mount the seat. ( p. 78) 14.11 Changing the tail light bulbs Note Damage to reflector Reduced brightness. –...
  • Page 139 ELECTRICAL SYSTEM Main work – Remove screws – Remove the grab handles. B00641-10 – Remove screws on the left and right heat protectors. – Remove the heat protectors. C00355-10...
  • Page 140 ELECTRICAL SYSTEM – Remove screws on the left and right rear side parts. – Remove screws – Remove the rear side parts. C00356-10 – Remove screws – Remove the rear top part. B00644-10...
  • Page 141 ELECTRICAL SYSTEM – Carefully pull bulb sockets out of the holder. – Remove the bulb. – Position a new light bulb in the socket. Tail light (WR5W/socket W2.1x9.5d) ( p. 195) – Carefully position the sockets with the bulbs into the holder in the tail light. –...
  • Page 142 ELECTRICAL SYSTEM – Position the rear side parts. – Mount and tighten screws on the left and right rear side parts. Guideline Screw, rear side part EJOT Altracs Initial screw con- 50x16 nection 3.3 Nm (2.43 lbf ft) Subsequent screw connection 2 Nm (1.5 lbf ft) –...

  • Page 143: Changing The License Plate Lamp

    ELECTRICAL SYSTEM – Position the grab handles. – Mount and tighten screws Guideline Screw, handrail 20 Nm (14.8 lbf ft) B00641-10 Finishing work – Mount the seat. ( p. 78) 14.12 Changing the license plate lamp Main work – Remove screws –...
  • Page 144 ELECTRICAL SYSTEM – Carefully pull socket out of the holder. – Remove the bulb. – Position a new light bulb in the holder. License plate lamp (W5W/socket W2.1x9.5d) ( p. 195) – Carefully position the socket with the bulb into the holder. 700603-01 –...

  • Page 145: Checking The Headlight Setting

    ELECTRICAL SYSTEM 14.13 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark 0 0 A at the level of the center of the headlight. – Make another mark at a distance of under the first mark.

  • Page 146: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM Main work – Turn adjusting wheel to adjust the headlight range. 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 headlight adjustment).
  • Page 147 ELECTRICAL SYSTEM Loss of a black ignition key (second black ignition key available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Press the emergency OFF switch into the position 401184-10 – Insert the orange programming key in the ignition lock.
  • Page 148 ELECTRICAL SYSTEM Immobilizer indicator lamp lights up, switches off briefly and flashes; the number of flashes equals the number of functional black ignition keys includ- ing the orange programming key. In this case, twice. – Switch off the ignition by turning the orange programming key to the OFF position –...
  • Page 149 ELECTRICAL SYSTEM – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. All black ignition keys are deactivated. – Order a new black ignition key according to the key number on the KEYCODECARD and activate it.
  • Page 150 ELECTRICAL SYSTEM The immobilizer indicator lamp lights up, switches off briefly and flashes; the number of flashes equals the number of functional black ignition keys including the orange programming key. – Switch off the ignition by turning the orange programming key to the OFF position –...

  • Page 151: 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) B00676-10 Cooling takes place by means of the air stream and a radiator fan, which is controlled by a...
  • Page 152 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 153 COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 202) » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! – Fill/bleed the cooling system. p.

  • Page 154: 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 155: Draining The Coolant

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 202) – Mount the cover of the compensating tank. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! –...

  • Page 156: Filling/Bleeding The Cooling System

    COOLING SYSTEM Main work – Place a suitable container under the radiator. – Remove radiator cap – Remove screw – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) C00351-10 –...
  • Page 157 COOLING SYSTEM Preparatory work – Remove the seat. ( p. 77) – Remove the mask spoiler. ( p. 81) – Reset the fuel tank. ( p. 78) Main work – Ensure that the drain plug on the radiator and the water pump cover are tightened. –...
  • Page 158 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 Alternative 1 Coolant ( p. 202) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 159: 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 160: 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 161: Adjusting The Ignition Curve To The Fuel Quality

    TUNING THE ENGINE 16.4 Adjusting the ignition curve to the fuel quality Preparatory work – Switch off the ignition by turning the ignition key to the OFF position. – Remove the seat. ( p. 77) To activate the ignition curve for low octane fuel: Note Engine failure Low-quality fuel damages the engine.

  • Page 162: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16.5 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
  • Page 163 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 164: 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 165: 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. 163) – Fill up with engine oil. p. 168) 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 166 SERVICE WORK ON THE ENGINE – 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. 700611-10 – Remove screws and cover 700610-10 –...
  • Page 167 SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove oil drain plug – Fully drain the engine oil out of the oil tank. – Remove screws and move oil line to one side. 700613-10 –...
  • Page 168 SERVICE WORK ON THE ENGINE – Insert oil filter – Lubricate the O-ring of the oil filter cover. – Mount the oil filter cover . Mount and tighten the screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) – Position the oil line.
  • Page 169 SERVICE WORK ON THE ENGINE – Position oil line . Mount and tighten screws Guideline Remaining engine screws 10 Nm (7.4 lbf ft) – Mount oil drain plug with the magnet and new seal and tighten. Guideline Oil drain plug with magnet M12x1.5 25 Nm (18.4 lbf ft)

  • Page 170: Filling Up With Engine Oil

    SERVICE WORK ON THE ENGINE 17.4 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – The oil must be added in two steps. Engine oil 3.0 l (3.2 qt.) External Engine oil temperature:...

  • Page 171: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the plug. – Add engine oil to the top marking – Mount the plug. 17.5 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. The engine oil level must be corrected when the engine is warm.

  • Page 172: 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 173 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 174: 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. 207) – Lubricate the ignition/steering lock. Universal oil spray ( p.
  • Page 175 CLEANING, CARE – Clean the chain. ( p. 84)

  • Page 176: 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 177 – 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. 75) – Raise the motorcycle with the front wheel stand. ( p.

  • Page 178: Preparing For Use After Storage

    STORAGE 19.2 Preparing for use after storage – Take the motorcycle off of the front wheel stand. ( p. 76) – Take the motorcycle off of the rear wheel stand. ( p. 75) – Recharge the battery. p. 120) – Install the battery.

  • Page 179: 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...
  • Page 180 Possible cause Action – Engine has too little power Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine overheats Too little coolant in cooling system Check the cooling system for leaks.
  • Page 181 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil too thin (low viscosity) Change the engine oil and filter, clean the oil screens. p. 163) – The headlight and tail light are not Fuse 2 blown Change the fuses of individual power consumers. functioning p.

  • Page 182: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Blink code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition ICU antenna malfunction Blink code of immobilizer indica-...
  • Page 183 IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition ICU is not activated Blink code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica-...

  • Page 184: Engine Control Blink Code

    ENGINE CONTROL 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 185 ENGINE CONTROL 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...
  • Page 186 ENGINE CONTROL 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...
  • Page 187 ENGINE CONTROL 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 188 ENGINE CONTROL 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 189 ENGINE CONTROL BLINK CODE Blink code of FI warning lamp (MIL) 81 FI warning lamp (MIL) flashes 8x long, 1x short Error level condition Immobilizer control unit - circuit fault 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 190: Technical Data

    TECHNICAL DATA 23.1 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 191: Engine Tightening Torques

    TECHNICAL DATA 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 Mixture preparation Electronic fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug NGK LKAR8BI9 Spark plug electrode gap 0.8 mm (0.031 in) Cooling Water cooling, permanent circulation of coolant by water pump...
  • Page 192 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 193 TECHNICAL DATA – 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) ® Screw, timing chain guide rail 15 Nm (11.1 lbf ft) Loctite 243™...

  • Page 194: Capacities

    TECHNICAL DATA – Engine coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) – Plus, cylinder head (2nd cylinder) M12x1.5 25 Nm (18.4 lbf ft) ® Plug, oil filter housing M14x1.5 15 Nm (11.1 lbf ft) Loctite 243™ ® Bleeder flange, alternator cover M16x1.5 10 Nm (7.4 lbf ft) Loctite...

  • Page 195: Fuel

    TECHNICAL DATA 23.3.3 Fuel Total fuel tank capacity, approx. 19 l (5 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 204) Fuel reserve, approx. 3.7 l (3.9 qt.) 23.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA PA...

  • Page 196: Electrical System

    TECHNICAL DATA 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) Rear 2.6 bar (38 psi) Secondary drive ratio 17:41 Chain 5/8 x 5/16” X‑ring Steering head angle 65.6°...

  • Page 197: Tires

    Rear tires 120/70 ZR 17 M/C 58W TL 180/55 ZR 17 M/C 73W TL Continental ContiSportAttack Continental ContiSportAttack Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.7K.43 Fork WP Suspension Up Side Down 4860 ROMA PA...

  • Page 198: Shock Absorber

    TECHNICAL DATA Standard 20 clicks Sport 15 clicks Full payload 15 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring preload - Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer(s)
  • Page 199 TECHNICAL DATA Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks...

  • Page 200: Chassis Tightening Torques

    TECHNICAL DATA Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 204) 23.9 Chassis tightening torques – Remaining frame bolts EJOT Delta PT 50x12 1.2 Nm (0.89 lbf ft) – Remaining frame bolts EJOT PT K50x12 T20 1.2 Nm (0.89 lbf ft) –...
  • Page 201 TECHNICAL DATA – Remaining chassis nuts 10 Nm (7.4 lbf ft) – Remaining chassis screws 10 Nm (7.4 lbf ft) – Screw, cable guide 2 Nm (1.5 lbf ft) ® Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 202 TECHNICAL DATA – Screw, handlebar clamp 20 Nm (14.8 lbf ft) – Screw, handrail 20 Nm (14.8 lbf ft) ® Screw, ignition lock (ratchet screw) Loctite 243™ ® Screw, mask holder 15 Nm (11.1 lbf ft) Loctite 243™ ® Screw, rear brake disc 30 Nm (22.1 lbf ft) Loctite 243™...
  • Page 203 TECHNICAL DATA Screw connection, suction line M14x1.5 45 Nm (33.2 lbf ft) Loctite ® 577™ Screw, bottom shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased Screw, top shock absorber M14x1.5 80 Nm (59 lbf ft) Thread greased – Nut, oil line M16x1.5 25 Nm (18.4 lbf ft)

  • Page 204: 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 205 SAE ( p. 209) (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 206 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 207 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 208: 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 209 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 210 AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...

  • Page 211: 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 212: Index

    INDEX INDEX Brake light bulb changing ........131 ABS .
  • Page 213 INDEX Combination instrument clock, setting ....... . 33 Electric starter button ......27 coolant temperature indicator .
  • Page 214 INDEX fork legs, bleeding ......77 Headlight flasher switch ......25 rebound, adjusting .
  • Page 215 INDEX checks and maintenance measures when preparing for use . 50 Mask spoiler installing ........83 information on first use .
  • Page 216 INDEX tires ........195 Shifting .
  • Page 217 INDEX Winter operation checks and maintenance measures ....172 Work rules ........11...
  • Page 218 *3211957en* 3211957en 12/2012 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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