KTM 390 Duke EU 2013 Repair Manual
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KTM 390 Duke EU 2013 Repair Manual

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REPAIR MANUAL
2013
390 Duke EU
390 Duke AUS
390 Duke MAL
390 Duke 2014 COL
Art. no. 3206167en

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Table of Contents
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Summary of Contents for KTM 390 Duke EU 2013

  • Page 1 REPAIR MANUAL 2013 390 Duke EU 390 Duke AUS 390 Duke MAL 390 Duke 2014 COL Art. no. 3206167en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 11 FUEL TANK, SEAT, TRIM ........... 38 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 11.1 Opening the filler cap........38 Symbols used ........... 5 11.2 Closing the filler cap ........38 Formats used............ 5 11.3 Removing the seat .......... 38 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 14.11 Adding rear brake fluid ........73 16.4.6 Changing the balancer shaft bearing ... 111 14.12 Changing the rear brake fluid ......73 16.4.7 Work on the cylinder head ......112 15 LIGHTING SYSTEM, INSTRUMENTS ......75 16.4.8 Checking the cylinder head......
  • Page 6 TABLE OF CONTENTS 17 SHIFT MECHANISM..........147 17.1 Adjusting the shift lever......... 147 18 WATER PUMP, COOLING SYSTEM ......148 18.1 Draining the coolant ........148 18.2 Filling/bleeding the cooling system ....148 18.3 Checking the antifreeze and coolant level ..149 18.4 Checking the coolant level ......

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

  • Page 8: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

  • Page 9: Important Information

    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 & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: Serial Numbers

    SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the right of the steering head. The type label is on the right of the frame behind the steering head. 101877-10 Key number can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key.

  • Page 11: Motorcycle

    MOTORCYCLE 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 support of the wheel stand. –...

  • Page 12: Taking The Motorcycle Off Of The Front Wheel Stand

    MOTORCYCLE – Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem. Adapter (61029955620) ( p. 191) Front wheel stand (61029055500) ( p. 191) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. 101888-01 Taking the motorcycle off of the front wheel stand Note...

  • Page 13: Removing The Motorcycle From The Work Stand

    MOTORCYCLE – Mount special tool on the right side of the vehicle. Work stand (62529055000) ( p. 192) 308228-10 – Remove screw 308229-10 – Mount special tool on the left side of the vehicle. Work stand (62529055000) ( p. 192) 308230-10 –...

  • Page 14: Starting

    MOTORCYCLE – Mount and tighten screws Guideline Screw, engine bearer on frame 30 Nm (22.1 lbf ft) 308232-10 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 15: Starting The Motorcycle To Make Checks

    MOTORCYCLE Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running. – button for 3 – 5 seconds. Press the The ABS warning lamp starts flashing; ABS is deactivated.

  • Page 16: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs – Push dust boot of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

  • Page 17: Installing The Fork Legs

    FORK, TRIPLE CLAMP – Loosen screws . Remove the fork legs from the bottom. 308238-10 Installing the fork legs Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Main work –...

  • Page 18: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP – Position the brake calipers and check that the brake linings are seated correctly. – Mount screws but do not tighten yet. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
  • Page 19 FORK, TRIPLE CLAMP – Loosen the screw cap Info The screw cap cannot be removed yet. 201506-10 – Empty the fork oil. 201507-10 – Release the fork leg and clamp it with the fork stub. Info Use soft jaws. 201508-10 –...

  • Page 20: Checking The Fork Legs

    FORK, TRIPLE CLAMP – Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T612S) ( p. 197) – Remove dust boot 201512-10 – Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied. 201513-10 –...

  • Page 21: Assembling The Fork Legs

    FORK, TRIPLE CLAMP – Measure the outside diameter of the inner tube in several places. External diameter of inner tube 42.975… 43.005 mm (1.69193… 1.69311 in) » If the measured value is less than the specified value: – Change the fork leg. 200684-10 –...
  • Page 22 FORK, TRIPLE CLAMP – Slide on lock ring – Grease and slide on seal ring Lubricant (T511) ( p. 187) Info Mount with the sealing lip facing down and the open side facing up. – Slide on support ring – Sand the edges of sliding bushing with 600-grit sandpaper, then clean and grease.

  • Page 23: Removing The Lower Triple Clamp

    FORK, TRIPLE CLAMP – Mount screw cap onto the piston rod. Info must be turned all the way down. – Hold the screw cap and tighten the nut. Guideline Nut, piston rod on screw cap M12x1 30 Nm (22.1 lbf ft) 202097-10 –...
  • Page 24 FORK, TRIPLE CLAMP – Detach connectors 308244-10 – Detach connectors 308245-10 – Remove the connector holder. – Disconnect connector 308246-10 – Remove the combination instrument. 308247-10 – Remove screws – Remove the headlight mask. 308248-10 – Remove screw 308249-10...

  • Page 25: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP – Remove the upper triple clamp with the handlebar and set aside. Info Protect the vehicle and its attachments from damage by covering them. 308251-10 – Expose the cable. 308252-10 – Remove nut Castle nut wrench; ½" drive (90129050100) ( p.
  • Page 26 FORK, TRIPLE CLAMP Guideline Nut, steering head M30x1 Step 1 50 Nm (36.9 lbf ft) 2nd stage (loosen, counter- clockwise) 2 turns Step 3 5 Nm (3.7 lbf ft) Castle nut wrench; ½" drive (90129050100) ( p. 195) Alternative 2 The steering head bearing is used again.
  • Page 27 FORK, TRIPLE CLAMP – Position the combination instrument. – Plug in connector – Mount the connector holder 308246-11 – Plug in connectors 308245-11 – Plug in connectors 308244-11 – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm (8.1 lbf ft) 308243-11...

  • Page 28: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Finishing work – Check that the wiring harness, throttle cables, and brake line have the necessary freedom of movement and are correctly routed. – Check the steering head bearing play. ( p. 26) – Remove the motorcycle from the work stand. ( p.
  • Page 29 FORK, TRIPLE CLAMP – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Tighten screw Guideline Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) – Tighten screws Guideline Screw, top triple clamp 11 Nm (8.1 lbf ft) 308256-10 Finishing work...

  • Page 30: Handlebar, Controls

    HANDLEBAR, CONTROLS 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 back- wards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 31: Adjusting The Clutch Cable Play

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

  • Page 32: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial situation of the spring process on the shock absorber.

  • Page 33: Removing The Spring

    SHOCK ABSORBER, SWINGARM – Lift the link fork. – Mount and tighten screw Guideline Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft) – Tighten fitting Guideline Fitting, bottom shock absorber M10x1.25 45 Nm 308258-11 (33.2 lbf ft) Finishing work –...
  • Page 34 SHOCK ABSORBER, SWINGARM Alternative 1 – Tension the spring to the prescribed position by turning the adjusting ring. Guideline Spring preload Standard 3 clicks Full payload 10 clicks Hook wrench (T106S) ( p. 196) Alternative 2 201698-10 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior.

  • Page 35: Exhaust

    EXHAUST Removing the exhaust manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove nuts with the washers. – Swing the radiator forward slightly. 308293-10 –...

  • Page 36: Installing The Exhaust Manifold

    EXHAUST Installing the exhaust manifold – Position the exhaust manifold. 308297-10 – Mount nuts but do not tighten them yet. Guideline Nut, exhaust flange 22 Nm (16.2 lbf ft) 308296-11 – Position and tighten exhaust clamp Guideline Exhaust clamp 10 Nm (7.4 lbf ft) –...

  • Page 37: Removing The Main Silencer

    EXHAUST Removing the main silencer Preparatory work – Remove the exhaust manifold. ( p. 33) Main work – Remove screw with washers. 308299-10 – Remove screw with the sleeve. – Hang the brake fluid reservoir to the side. Info Ensure that brake fluid does not escape. 308300-10 –...

  • Page 38: Installing The Main Silencer

    EXHAUST Installing the main silencer Main work – Position the main silencer. 308303-10 – Mount and tighten screw Guideline Screw, main silencer 23 Nm (17 lbf ft) Info Make sure the sleeves are seated correctly. 308302-11 – Mount and tighten screw with the washers.

  • Page 39: Air Filter

    AIR FILTER 10.1 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Preparatory work –...

  • Page 40: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 11.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 41: Mounting The Seat

    FUEL TANK, SEAT, TRIM 11.4 Mounting the seat Main work – Attach seat recesses at screws and lower at the rear. – Mount and tighten screws Guideline Screw, seat 11 Nm (8.1 lbf ft) 101892-10 Finishing work – Mount the passenger seat. ( p.
  • Page 42 FUEL TANK, SEAT, TRIM Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
  • Page 43 FUEL TANK, SEAT, TRIM – Remove filler cap 308276-10 – Remove screws with the washers. 308277-10 – Remove screws – Remove screws 308278-10 – Remove cap from the compensating tank. 308279-10 – Remove screws 308280-10 – Lift the fuel tank cover. –...

  • Page 44: Installing The Fuel Tank Cover

    FUEL TANK, SEAT, TRIM – Push back hose clamp – Pull off the vent hose. – Remove the fuel tank cover. 308282-10 – Close the fuel tank with a suitable plug. 308283-10 11.8 Installing the fuel tank cover Danger Fire hazard Fuel is highly flammable. –...
  • Page 45 FUEL TANK, SEAT, TRIM – Position the fuel tank cover. – Attach the side cover on both sides. 308281-10 – Mount and tighten screws Guideline Remaining screws, chassis 5 Nm (3.7 lbf ft) 308280-11 – Mount plug of the compensating tank. 308279-11 –...

  • Page 46: Removing The Fuel Tank

    FUEL TANK, SEAT, TRIM – Mount and tighten screws with the washer. Guideline Screw, fuel tank 11 Nm (8.1 lbf ft) 308285-10 – Mount and tighten screws Guideline Screw, fuel tank trim 5 Nm (3.7 lbf ft) – Mount and tighten screws Guideline Screw, front seat fixing 5 Nm (3.7 lbf ft)

  • Page 47: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM – Remove screws 308287-10 – Take off the holder 308288-10 – Detach connector 308289-10 – Detach the fuel line with a suitable tool 308290-10 – Push back hose clamp – Pull off the fuel line and remove the fuel tank. 308291-10 11.10 Installing the fuel tank...
  • Page 48 FUEL TANK, SEAT, TRIM Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 49: Removing The Front Spoiler

    FUEL TANK, SEAT, TRIM – Position the EFI control unit. – Mount and tighten screws Guideline Screw, EFI control unit 4 Nm (3 lbf ft) 308286-11 Finishing work – Install the fuel tank cover. ( p. 42) – Mount the seat. ( p.

  • Page 50: Dismounting The Front Fender

    FUEL TANK, SEAT, TRIM 11.13 Dismounting the front fender – Remove screws . Remove the front fender. 308234-10 11.14 Installing the front fender – Position the front fender. Mount and tighten screws Guideline Screw, front fender 11 Nm (8.1 lbf ft) 308234-10 11.15 Checking the fuel pressure...

  • Page 51: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM – Mount special tool 0 0 3 Pressure testing tool (61029094000) ( p. 191) – with the nozzle code 0,45. Mount special tool Testing hose (61029093000) ( p. 191) – Position the hose end in a fuel can. 0 0 2 Guideline Minimum size of fuel can...
  • Page 52 FUEL TANK, SEAT, TRIM 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. Preparatory work – Remove the passenger seat. ( p.

  • Page 53: Replacing The Fuel Pump

    FUEL TANK, SEAT, TRIM 11.17 Replacing the fuel pump Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 54: Wheels

    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. Info The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.

  • Page 55: Checking The Brake Discs

    WHEELS » If a tire is more than 5 years old: – Change the tires. 12.3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement Info...

  • Page 56: Removing The Brake Disc Of The Front Brake

    WHEELS Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers. Long-life grease ( p.

  • Page 57: Rear Wheel

    WHEELS Finishing work – Install the front wheel. ( p. 53) – Take the motorcycle off of the rear wheel stand. ( p. 9) 12.5 Rear wheel 12.5.1 Removing the rear wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p.

  • Page 58: Removing The Brake Disc Of The Rear Brake

    WHEELS – Pull the rear wheel back and mount wheel spindle with the washer and chain adjuster Info Mount the left and right chain adjusters in the same position. – Mount nut and washer. – Push the rear wheel forward so that the chain adjusters are on the screws, and tighten nut Guideline In order for the rear wheel to be correctly aligned, the markings on the left and...

  • Page 59: Checking The Chain Tension

    WHEELS – Position the ABS sensor wheel. – Mount and tighten screws Guideline Screw, ABS sensor wheel 12 Nm Loctite ® 243™ (8.9 lbf ft) 307350-11 Finishing work – Install the rear wheel. ( p. 55) – Take the motorcycle off of the rear wheel stand. ( p.

  • Page 60: Checking The Chain, Rear Sprocket, And Engine Sprocket

    WHEELS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5… 7 mm (0.2… 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 61: Cleaning The Chain

    WHEELS – Remove screws and release screw . Push the chain guard aside. B01416-10 – Check the chain sliding guard for wear. » If drill hole becomes visible on the chain sliding guard in area – Change the chain sliding guard. –...

  • Page 62: Checking The Rear Hub Rubber Dampers

    WHEELS Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. –...

  • Page 63: Wiring Harness, Battery

    WIRING HARNESS, BATTERY 13.1 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 64: Disconnecting The Negative Cable Of The Battery

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Info Even when there is no load on the battery, it still loses power steadily.

  • Page 65: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( p. 39) – Remove the seat. ( p. 38) – Disconnect the negative cable of the battery to avoid damage to the motorcycle's electronics.

  • Page 66: Changing The Fuses Of Individual Power Consumers

    WIRING HARNESS, BATTERY 13.7 Changing the fuses of individual power consumers Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the passenger seat. Preparatory work – Switch off all power consumers and switch off the engine. –...

  • Page 67: Brake System

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 68 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane 307304-10 – Remove locking clip 307305-10 – Remove pin – Take off springs 307306-10 – Remove brake linings –...

  • Page 69: Checking The Brake Fluid Level Of The Front Brake

    BRAKE SYSTEM – Position springs The arrow on the spring points in the direction of travel. – Mount pin Info Make sure the springs are seated correctly. – Activate the hand brake lever until there is a firm pressure point. 307306-10 –...

  • Page 70: Changing The Front Brake Fluid

    BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 71: Checking The Rear Brake Linings

    BRAKE SYSTEM – Open shut-off valve Info Follow the operating instructions of the bleeding device. – Ensure that the filling pressure is set on pressure gauge . Correct the filling pres- sure on pressure regulator if necessary. Guideline Filling pressure 2…...

  • Page 72: Changing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 73: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Position brake linings – Mount pin 308265-10 – Mount locking clips 308263-11 – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. – Add brake fluid to the MAX marking.

  • Page 74: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 14.9 Adjusting the free travel of the foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.

  • Page 75: Adding Rear Brake Fluid

    BRAKE SYSTEM 14.11 Adding rear brake fluid Warning Danger of accidents Failure of the brake system. – 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. Warning Skin irritation Brake fluid can cause skin irritation on contact.
  • Page 76 BRAKE SYSTEM – Cover painted parts. – Remove screw cap with membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Bleed syringe (50329050000) ( p. 189) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 77: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 15.1 Setting kilometers or miles Info Make the country-specific setting. Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE button for 5 - 10 seconds. The display changes from km/h to mph or from mph to km/h.

  • Page 78: Setting The Time

    LIGHTING SYSTEM, INSTRUMENTS – Do not activate the two buttons for approx. 15 seconds. The display RPM 2 goes out and the set speed is stored. 15.4 Setting the time Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display.

  • Page 79: Adjusting The Headlight Range

    LIGHTING SYSTEM, INSTRUMENTS 15.7 Adjusting the headlight range Main work – Remove expanding rivets 101907-10 – Remove screws – Lift the headlight mask slightly and swing forward. 101908-10 – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking headlight adjustment).

  • Page 80: Changing The Parking Light Bulb

    LIGHTING SYSTEM, INSTRUMENTS 15.8 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 81: Changing The Headlight Bulb

    LIGHTING SYSTEM, INSTRUMENTS – Position cover – Mount and tighten screws B00762-10 – Fold the headlight mask up. – Mount and tighten screws Guideline Screw, headlight mask 11 Nm (8.1 lbf ft) 308243-10 – Mount expanding rivets on both sides. –...
  • Page 82 LIGHTING SYSTEM, INSTRUMENTS – Take off protection cap – Disconnect plug-in connector B00760-10 – Detach retaining clamp – Remove headlight bulb – Position the new headlight bulb in the headlight housing. Headlight (H4/socket P43t) ( p. 160) Info Insert the headlight bulb so that the catches latch into the recesses. –...

  • Page 83: Engine

    ENGINE 16.1 Removing the engine Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 9) – Remove the front spoiler. ( p. 47) – Remove the passenger seat. ( p. 39) – Remove the seat. ( p.
  • Page 84 ENGINE – Detach spark plug connector 308309-10 – Remove screws – Remove screw – Take off the engine sprocket cover. 308310-10 – Remove screws and take off the lock washer. 308311-10 – Remove nut with washer. – Take off chain adjuster –...
  • Page 85 ENGINE – Push back the rubber cap. – Remove nut with washer. 308315-10 – Expose the cable and unplug connectors 308316-10 – Expose the cable and unplug connector 308317-10 – Release hose clip – Push the throttle valve body upward out of the intake flange. 308318-10 –...
  • Page 86 ENGINE – Push back hose clamp – Pull off the radiator hose. 308321-10 – Remove screws – Pull off the radiator pipe and hang it to one side. 308322-10 – Remove screws – Take off the retaining bracket. 308323-10 – Position the floor jack under the engine and fix it using the special tool.

  • Page 87: Installing The Engine

    ENGINE – Lower the engine. Info You should have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage. 308326-10 16.2 Installing the engine Preparatory work – Lift the motor onto the special tool and secure it.
  • Page 88 ENGINE – Position the retaining bracket. – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 308323-11 – Mount the radiator pipe with the O-ring. – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 308322-11 –...
  • Page 89 ENGINE – Position the throttle valve body in the intake flange. – Tighten hose clip 308318-11 – Plug in connector – Position the cable and secure with cable binders. 308317-11 – Plug in connectors – Position the cable and secure with cable binders. 308316-11 –...
  • Page 90 ENGINE – Pull the rear wheel toward the rear. – Mount chain adjuster – Mount and tighten nut with the washer. Guideline For the rear wheel to be aligned correctly, the markings on the left and right of the chain adjuster must be in the same position as the reference marks. Nut, rear wheel spindle M14x1.5 90 Nm...
  • Page 91 Fit the front spoiler. ( p. 47) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leak tightness. – Check the engine oil level. ( p. 152) –...

  • Page 92: Disassembling The Engine

    ENGINE 16.3 Disassembling the engine 16.3.1 Preparations – Mount special tools on the engine assembly stand. Engine fixing arm (90129002060) ( p. 194) Engine fixing arm (90129002050) ( p. 193) Engine assembly stand (61229001000) ( p. 192) – Mount the engine on special tool. Info Have an assistant help you or use a crane.

  • Page 93: Removing The Valve Cover

    ENGINE 16.3.4 Removing the valve cover – Remove screws with the gasket. – Take off the valve cover with the valve cover seal. 307961-10 – Take off gasket 307962-10 – Remove the spark plug shaft insert 307963-10 16.3.5 Removing the spark plug –...

  • Page 94: Setting The Engine To Ignition Top Dead Center

    ENGINE – Take off the clutch cover. Info Pull the clutch lever forward slightly. 307973-10 – Remove dowels – Take off clutch cover gasket 307974-10 16.3.7 Setting the engine to ignition top dead center – Remove screw plug 307967-10 – Remove screw plug 307968-10 –...

  • Page 95: Removing The Timing Chain Tensioner

    ENGINE – Remove screw 307975-10 – Mount special tool Engine blocking screw (61229015000) ( p. 192) 307976-10 16.3.8 Removing the timing chain tensioner – Remove screw with the O-ring. 307978-10 – Turn the timing chain tensioner screw clockwise. The timing chain tensioner is locked. –...

  • Page 96: Removing The Cylinder Head

    ENGINE – Remove intake camshaft 307982-10 – Remove exhaust camshaft 307983-10 16.3.10 Removing the cylinder head – Remove screws 307985-10 – Release screws in a crisscross pattern and remove them with the washers. – Take off the cylinder head. 307986-10 –...

  • Page 97: Removing The Piston

    ENGINE 16.3.11 Removing the piston – Push the cylinder upward. Info Push the cylinder upward only far enough to allow removal of the piston pin. – Remove piston pin retainer – Remove the piston pin. – Take off the cylinder with the piston. –...

  • Page 98: Removing The Water Pump Wheel

    ENGINE 16.3.14 Removing the water pump wheel – Remove screws – Remove the water pump cover with the gasket. 308000-10 – Remove locating pins 308001-10 – Remove nut with washer. – Take off the water pump impeller 308002-10 16.3.15 Removing the alternator cover –...

  • Page 99: Removing The Rotor

    ENGINE 16.3.16 Removing the rotor – Remove screw with the washer. 308005-10 – Mount special tool in the crankshaft. Pressure screw for crankshaft (90129020000) ( p. 194) – Mount special tool on the rotor. Info Left-handed thread! – Hold it tight using the special tool and pull off the rotor by turning the screw in. 308066-10 Puller for rotor (90229009000) ( p.

  • Page 100: Removing The Balancer Shaft Drive Wheel

    ENGINE 16.3.18 Removing the balancer shaft drive wheel – Remove screw with the washer. 308010-10 – Remove balancer shaft gear with a wedge. 308011-10 – Remove nut with washers. Castle nut wrench; ½" drive (90129022000) ( p. 194) – Take off drive wheel of the balancer shaft. –...

  • Page 101: Removing The Suction Pump

    ENGINE – Remove contact pin and the contact spring. 308016-10 16.3.20 Removing the suction pump – Remove screws – Take off the oil pump housing of the suction pump. 308017-10 – Remove dowels 308018-10 – Remove external rotor and internal rotor 308019-10 –...

  • Page 102: Removing The Spacer

    ENGINE 16.3.21 Removing the spacer – Remove the spacer of the countershaft. 308022-10 16.3.22 Removing the clutch cage – Loosen screws in a crisscross pattern and remove together with the washers and the clutch springs. – Take off pressure cap 308023-10 –...

  • Page 103: Removing The Primary Gear

    ENGINE – Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub. – Take off clutch basket 308027-10 – Remove collar sleeve 308028-10 16.3.23 Removing the primary gear – Remove nut with washer. 308030-10 –...

  • Page 104: Removing The Force Pump

    ENGINE – Remove woodruff key 308034-10 16.3.24 Removing the force pump – Remove lock ring – Take off washer – Remove the oil pump gear 308035-10 – Remove pin – Take off the washer. 308036-10 – Remove screws – Take off the pressure pump housing. 308037-10 –...

  • Page 105: Removing The Shift Shaft

    ENGINE – Remove pin – Remove the oil pump shaft 308040-10 16.3.25 Removing the shift shaft – Push sliding plate away from the shift drum locating . Remove shift shaft with the washer. 308044-10 16.3.26 Removing the shift drum locating –...

  • Page 106: Removing The Left Engine Case

    ENGINE – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 189) 308048-10 16.3.29 Removing the left engine case – Remove special tool Engine blocking screw (61229015000) ( p. 192) 308055-10 – Remove screw 308056-10 308057-10 –...

  • Page 107: Removing The Shift Rails

    ENGINE – Mount special tool Pressure screw for crankshaft (90129020000) ( p. 194) 308067-10 – Mount special tool with suitable screws. Case separating tool (90129048100) ( p. 195) Info Use the drill hole marked with 902. – Pull off the section of the engine case by screwing in the screw. Info 308068-10 Do not wedge the engine case section.

  • Page 108: Removing The Shift Forks

    ENGINE 16.3.32 Removing the shift forks – Remove shift forks 308061-10 16.3.33 Removing the transmission shafts – Pull both transmission shafts out of the bearing seats together. 308063-10 16.3.34 Removing the balancer shaft – Remove screw – Take off the lock washer. –...

  • Page 109: Work On Individual Parts

    ENGINE 16.4 Work on individual parts 16.4.1 Work on the left section of the engine case – Remove all dowels. – Remove lock ring – Remove shaft seal ring of the shift shaft and of the countershaft. – Remove oil nozzle –...

  • Page 110: Work On The Right Section Of The Engine Case

    ENGINE 16.4.2 Work on the right section of the engine case – Remove all dowels. – Remove screws . Remove the bearing retainers. – Remove oil nozzle – Remove nozzle – Remove any sealing mass remnants and clean the engine case section thoroughly. –...

  • Page 111: Checking The Radial Play Of The Lower Conrod Bearing

    ENGINE – Remove shaft seal ring 308076-10 – Remove shaft seal ring – Press the new shaft seal ring in all the way with the open side facing inward. Mounting sleeve (90129043000) ( p. 195) 308077-10 – Press shaft seal ring all the way in with the open side facing inward.

  • Page 112: Changing The Conrod Bearing

    ENGINE – Clamp the connecting rod with soft jaws. – Position the crankshaft. – Position the bearing shells. Insert the Plastigauge clearance gauge offset by 90° to the bearing face. Plastigauge measuring strips (60029012000) ( p. 190) – Position the conrod bearing cover. Mount and tighten the screws. Guideline Screw, conrod bearing M8x1...

  • Page 113: Changing The Balancer Shaft Bearing

    ENGINE – Measure the crank pin diameter. Guideline Crankshaft – diameter, crank pin Crankshaft classification A 31.970… 31.977 mm (1.25866… 1.25893 in) Crankshaft classification B 31.978… 31.985 mm (1.25897… 1.25925 in) Info The crankshaft classification is indicated by marking – Check the radial play of the lower conrod bearing.

  • Page 114: Work On The Cylinder Head

    ENGINE – Press on the balancer shaft bearing with a suitable tool. – Remove the special tools. Disassembly tool, balancer shaft bearing (90129056000) ( p. 196) 308072-10 16.4.7 Work on the cylinder head – Fold cam lever – Take the shims out of the valve spring retainers and lay them to one side accord- ing to their normal built-in position.

  • Page 115: Checking The Cylinder Head

    ENGINE 16.4.8 Checking the cylinder head – Check valve guides with the special tool. Limit plug gauge (77029026000) ( p. 193) » If the special tool is easy to insert into the valve guide: – Change the valve guides and valves. –...

  • Page 116: Checking/Measuring The Cylinder

    ENGINE – Position camshaft bearing bridge – Mount the screws and tighten in a crisscross pattern from the inside to the outside. Guideline Screw, camshaft bearing bridge 11 Nm (8.1 lbf ft) Info Make sure the dowel pins are seated correctly. Do not twist the camshaft.

  • Page 117: Checking/Measuring The Piston

    ENGINE » If the cylinder wear is within the tolerance range: – Change the piston ring. – Mount the piston ring with the marking facing toward the piston head. 16.4.12 Checking/measuring the piston – Check the piston bearing surface for damage. »...

  • Page 118: Checking The Oil Pressure Regulator Valve

    ENGINE – With special tool , check the play between the internal rotor and external rotor and between the external rotor and the oil pump housing. Feeler gauge (59029041100) ( p. 190) Oil pump Play between external rotor and 0.10… 0.20 mm (0.0039… internal rotor 0.0079 in) Oil pump...

  • Page 119: Checking The Clutch

    ENGINE 16.4.16 Checking the clutch 308085-01 – Check collar sleeve for damage and wear. » If there is damage or wear: – Change the collar sleeve. – Check the length of clutch springs ≥ 37 mm (≥ 1.46 in) Clutch spring - length »...

  • Page 120: Checking The Shift Mechanism

    ENGINE » If the intermediate discs are not level or are pitted: – Replace all intermediate discs. 16.4.17 Checking the shift mechanism 308086-01 – Check the shift forks (see ) for damage and wear (visual check). » If there is damage or wear: –...

  • Page 121: Preassembling The Shift Shaft

    ENGINE – Preassemble the shift shaft. ( p. 119) – Check the play between the sliding plate and the shift quadrant. Shift shaft – play in sliding plate/shift 0.15… 0.45 mm (0.0059… quadrant 0.0177 in) » If the measured value does not equal the specified value: –...

  • Page 122: Dismantling The Countershaft

    ENGINE 16.4.20 Dismantling the countershaft 308094-01 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws – Remove stop disk and the 1st-gear idler gear – Remove collar bushing – Remove the 6th-gear sliding gear –...

  • Page 123: Assembling The Main Shaft

    ENGINE 308098-01 – Check collar bushings for damage and wear. » If there is damage or wear: – Change the collar bushings. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...

  • Page 124: Assembling The Countershaft

    ENGINE Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 120) 308097-01 Main work – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws – Mount sixth-gear idler gear –...
  • Page 125 ENGINE 308095-01 Main work – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws – Mount collar bushing – Mount second-gear idler gear – Mount the fifth-gear sliding gear with the shift groove facing upward. –...

  • Page 126: Checking The Timing Assembly

    ENGINE 16.4.24 Checking the timing assembly 308087-01 – Check timing chain for damage and wear. » If there is damage or wear: – Change the timing chain. – Let the timing chain hang down freely. Check that the timing chain links move easily. »...

  • Page 127: Checking The Electric Starter Drive

    ENGINE – Remove screws – Remove the stator. – Position the new stator. – Mount and tighten screws Guideline Screw, stator 8 Nm Loctite ® 243™ (5.9 lbf ft) 308093-01 – Position the cable guide in the alternator cover. – Position the cable retainer.

  • Page 128: Checking The Freewheel

    ENGINE – Replace the starter motor. 16.4.27 Checking the freewheel – Insert freewheel gear into the freewheel hub by turning the freewheel gear clock- wise; do not wedge! – Check the locking action of the freewheel gear. » If the freewheel gear does not turn clockwise or if it does not lock counterclock- wise: –...

  • Page 129: Installing The Transmission Shafts

    ENGINE 16.5.3 Installing the transmission shafts – Oil the bearing. – Slide both transmission shafts into the bearing seats together. 308063-10 16.5.4 Installing the shift forks – Oil all parts carefully before assembling. – Shift fork has a smaller inside diameter; mount it in the shift groove of the main shaft.

  • Page 130: Installing The Left Engine Case

    ENGINE 16.5.7 Installing the left engine case – Clean the sealing areas. – Mount dowels 308058-11 – Mount the new O-rings on oil spray tube – Mount the oil spray tube. Catch engages in recess – Apply sealing compound to the left section of the engine case. Loctite ®...

  • Page 131: Installing The Oil Filter

    ENGINE – Mount and tighten screw Guideline Screw, engine case M6x35 12 Nm (8.9 lbf ft) 309201-10 – Position crankshaft to TDC and block with special tool Engine blocking screw (61229015000) ( p. 192) 309202-10 16.5.8 Installing the oil filter –...

  • Page 132: Installing The Shift Drum Locating

    ENGINE 16.5.10 Installing the shift drum locating – Mount spacer ring on the shift drum locating unit. – Press locking lever away from the shift drum locating and position the shift drum locating Pins engage in hole – Release the locking lever. –...

  • Page 133: Installing The Primary Gear

    ENGINE – Position the oil pump shaft with the internal rotor in the pressure pump housing. – Position external rotor in the pressure pump housing. Markings are visible after assembly. 308043-10 – Check that the oil holes are clear and fill with a small amount of oil. –...

  • Page 134: Installing The Clutch Cage

    ENGINE – Mount timing chain sprocket 308032-10 – Mount washer 308031-11 – Mount and tighten nut with the washer. Guideline Nut, primary gear/timing M16x1.5 120 Nm Loctite ® 243™ chain sprocket (88.5 lbf ft) 308030-11 16.5.14 Installing the clutch cage –...

  • Page 135: Installing The Spacer

    ENGINE – Mount nut with the washer. Hold the inner clutch hub with the special tool and tighten the nut. Guideline Nut, inner clutch hub M16LHx1.5 120 Nm Loctite ® 243™ (88.5 lbf ft) Clutch holder (51129003000) ( p. 189) 308026-10 –...

  • Page 136: Installing The Suction Pump

    ENGINE 16.5.16 Installing the suction pump – Position pin 308020-11 – Mount internal rotor and external rotor Marking of the external rotor is not visible after assembly. 308021-10 – Mount dowels 308018-11 – Oil the oil pump. – Position the oil pump housing. –...

  • Page 137: Installing The Gear Position Sensor

    ENGINE 16.5.17 Installing the gear position sensor – Mount the contact spring and contact pin The rounded sides of the contact pins face the sensor. 308016-11 – Install the gear position sensor. – Mount and tighten screws Guideline Screw, gear sensor 6 Nm Loctite ®...

  • Page 138: Installing The Starter Drive

    ENGINE – Mount and tighten nut Guideline Nut, drive wheel for balancer shaft 60 Nm (44.3 lbf ft) Castle nut wrench; ½" drive (90129022000) ( p. 194) 308012-10 – Position balancer shaft gear Markings align. – Mount wedge 308052-10 – Mount and tighten screw Guideline Screw, balancer shaft gear...

  • Page 139: Installing The Rotor

    ENGINE 16.5.20 Installing the rotor – Mount the spring washer. – Mount the rotor. Info Turn the freewheel gear counterclockwise to simplify assembly. – Mount and tighten screw Guideline Rotor screw 75 Nm Loctite ® 243™ 308005-10 (55.3 lbf ft) 16.5.21 Installing the alternator cover –...

  • Page 140: Installing The Timing Chain

    ENGINE – Mount the water pump cover with the seal ring. – Mount screws and tighten them in a crisscross pattern. Guideline Screw, water pump cover 12 Nm (8.9 lbf ft) 308000-11 16.5.23 Installing the timing chain – Feed in the timing chain tensioning rail from above. –...
  • Page 141 ENGINE – Position the piston with the special tool on the cylinder. – Carefully slide the piston into the cylinder from the top. Info The piston rings should not become caught; otherwise, they may be dam- aged. 307993-10 – Ensure that piston marking faces the outfeed side.

  • Page 142: Installing The Cylinder Head

    ENGINE – Cover the engine case opening with a cloth. – Position piston ring lock 6-o'clock position. – Insert the special tool and firmly press it toward the piston. Insert for piston pin retainer (77329030100) ( p. 193) – Turn the special tool clockwise, thereby pressing the piston pin retainer into the groove.

  • Page 143: Installing The Camshafts

    ENGINE – Mount and tighten screws Guideline Cylinder head screw 12 Nm (8.9 lbf ft) 307985-11 16.5.27 Installing the camshafts – Oil the camshafts and pivot points. – Ensure that the crankshaft is blocked in the TDC position. – Pull up the timing chain and insert exhaust camshaft –...

  • Page 144: Checking The Valve Clearance

    ENGINE – Holding it with the correct orientation, mount the timing chain tensioner with the gasket. – Mount and tighten screws Guideline Screw, timing chain tensioner 12 Nm (8.9 lbf ft) 307980-10 – Unlock the timing chain tensioner screw counterclockwise. –...

  • Page 145: Adjusting The Valve Clearance

    ENGINE – Mount and tighten screw plug Guideline Screw plug, alternator cover M24x1.5 10 Nm (7.4 lbf ft) 307967-11 – Remove special tool Engine blocking screw (61229015000) ( p. 192) 307976-11 – Mount and tighten screws Guideline Screw plug 12 Nm (8.9 lbf ft) 307975-11 16.5.30 Adjusting the valve clearance Preparatory work...

  • Page 146: Installing The Spark Plug

    ENGINE – Position the clutch cover. Info Pivot the clutch lever. 307973-10 – Mount and tighten screws Guideline Screw, clutch cover 12 Nm (8.9 lbf ft) 307972-11 16.5.32 Installing the spark plug – Mount and tighten the spark plug using special tool Guideline Spark plug 15 Nm...

  • Page 147: Installing The Chain Securing Guide

    ENGINE – Degrease the sealing areas and thinly coat with sealant in areas Loctite ® 5910 – Position the gasket in the valve cover. 307964-10 – Position the valve cover with the gasket. – Mount and tighten screws with the gaskets. Guideline Screw, valve cover 12 Nm (8.9 lbf ft)

  • Page 148: Removing The Engine From The Engine Assembly Stand

    ENGINE – Mount oil screen with the O-ring. 307958-10 – Mount and tighten oil drain plug with the O-ring. Guideline Oil drain plug M24x1.5 15 Nm (11.1 lbf ft) 307957-11 16.5.36 Removing the engine from the engine assembly stand – Remove the fitting from special tools Engine fixing arm (90129002060) ( p.

  • Page 149: Shift Mechanism

    SHIFT MECHANISM 17.1 Adjusting the shift lever Info The adjustment range of the shift lever is limited. – Loosen nuts – Adjust the shift lever by turning shift rod Guideline Shift rod adjustment range 110… 122 mm (4.33… 4.8 in) Info Make the same adjustments on both sides.

  • Page 150: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM 18.1 Draining the coolant 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 151: Checking The Antifreeze And Coolant Level

    WATER PUMP, COOLING SYSTEM – Rest the vehicle on the side stand. 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 ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 152: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM – Remove radiator cap – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled.
  • Page 153 WATER PUMP, COOLING SYSTEM » If you had to add more coolant than the specified amount: > 0.20 l (> 0.21 qt.) – Fill/bleed the cooling system. ( p. 148) – Mount the radiator cap.

  • Page 154: Lubrication System

    LUBRICATION SYSTEM 19.1 Oil circuit Suction pump Force pump Oil filter Oil pressure regulator valve Oil jet for piston cooling Oil spray tube Oil jet for cam follower lubrication 308470-10 19.2 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work –...
  • Page 155 LUBRICATION SYSTEM – Remove oil filter Circlip pliers reverse (51012011000) ( p. 189) 308271-10 – Position the special tool with the O-ring. Mount and tighten the screws. Guideline Screw, oil filter cover 8 Nm (5.9 lbf ft) Oil pressure adapter (75029094000) ( p.

  • Page 156: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM 19.4 Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 157: Adding Engine Oil

    LUBRICATION SYSTEM – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.6 l (1.7 qt.) Engine oil (SAE 15W/50) ( p. 186) – Install and tighten the oil filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

  • Page 158: Ignition System

    IGNITION SYSTEM 20.1 Alternator - checking the stator winding Stator winding, measurement I - check the resistance – Measure the resistance between the specified points. Stator, connector HB pin 1 – Stator, connector HB pin 2 Alternator ≤ 1 Ω Resistance of stator winding at: 20 °C (68 °F) »...

  • Page 159: Technical Data

    TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 375 cm³ (22.88 cu in) Stroke 60 mm (2.36 in) Bore 89 mm (3.5 in) Compression ratio 12.8:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 36 mm (1.42 in) Valve diameter, exhaust 29 mm (1.14 in)

  • Page 160: Engine Tightening Torques

    TECHNICAL DATA Wear limit 0.080 mm (0.00315 in) Crankshaft – diameter, crank pin Crankshaft classification A 31.970… 31.977 mm (1.25866… 1.25893 in) Crankshaft classification B 31.978… 31.985 mm (1.25897… 1.25925 in) Clutch facing discs – thickness of total package ≥ 21.30 mm (≥ 0.8386 in) ≥...

  • Page 161: Capacities

    TECHNICAL DATA – Oil pressure sensor 14 Nm (10.3 lbf ft) ® Rotor screw 75 Nm (55.3 lbf ft) Loctite 243™ ® Screw, camshaft drive sprocket 32 Nm (23.6 lbf ft) Loctite 243™ Screw, cylinder head 1st stage Thread is oiled, head flat is greased 30 Nm (22.1 lbf ft) 2nd stage...

  • Page 162: Electrical System

    Front tires Rear tires 110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under: http://www.ktm.com 21.8 Fork Fork part number 90101000044 Fork WP Suspension Fork length 736 mm (28.98 in)

  • Page 163: Chassis Tightening Torques

    TECHNICAL DATA 21.10 Chassis tightening torques – Exhaust clamp 10 Nm (7.4 lbf ft) – Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Screw, headlight EJOT PT ® 4 Nm (3 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) –...
  • Page 164 TECHNICAL DATA – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) – Screw, engine bearer on frame 30 Nm (22.1 lbf ft) ® Screw, foot brake lever 15 Nm (11.1 lbf ft) Loctite 243™ – Screw, fork stub 15 Nm (11.1 lbf ft) ®...

  • Page 165: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 22.1 Cleaning the 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 pressure can cause malfunctions or destroy these parts.

  • Page 166: Checks And Maintenance Steps For Winter Operation

    CLEANING/PROTECTIVE TREATMENT 22.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 167: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 9) –...

  • Page 168: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● Make the service entry in KTM DEALER.NET and in the service booklet.

  • Page 170: Wiring Diagram

    WIRING DIAGRAM 25.1 Page 1 of 9 bl-ye ye-rd wh-bl ye-bu ye-bu wh-gn wh-gn ye-rd ye-rd wh-or ye-rd bu-gr rd-gr wh-or gn-rd wh-br wh-gn wh-or gn-rd gn-rd bl-ye gn-rd gn-rd bu-gr wh-or bu-gr bu-gr wh-or wh-or 308201-01...
  • Page 171 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Vehicle control unit Fuse Fuse Battery Start auxiliary relay 1 Start auxiliary relay 2 Start auxiliary relay 3 Starter relay Starter motor Emergency OFF switch, electric starter button...

  • Page 172: Page 2 Of

    WIRING DIAGRAM 25.2 Page 2 of 9 wh-rd wh-bl wh-rd bu-gn bu-gn wh-rd wh-br wh-br wh-br wh-bu wh-bu wh-rd bu-or bl-ye bu-or wh-bl wh-br gn-pk gn-pk ye-gr bl-ye ye-gr wh-bl wh-bl bu-br bu-br bu-br ye-rd bu-br ye-rd bl-ye 308202-01...
  • Page 173 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Fuse Fuse Fuse Fuse Power relay Fuel pump relay Radiator fan relay Fuel pump Radiator fan Ignition/steering lock X293 Connector for accessory ground ACC 2 (not assigned) X294 Connector for accessory plug terminal 15 ACC 2 (not assigned)

  • Page 174: Page 3 Of

    WIRING DIAGRAM 25.3 Page 3 of 9 wh-bl wh-bl wh-bl HC/3 HB/3 bl-ye ye-bu ye-bu bu-gn bu-gn bl-ye bl-ye 308203-01...
  • Page 175 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Alarm system switch (optional) Fuse Alternator Combination instrument Voltage regulator X295 Diagnostics connector...

  • Page 176: Page 4 Of

    WIRING DIAGRAM 25.4 Page 4 of 9 wh-bl wh-bl wh-br wh-br wh-br bu-rd bu-rd ye-bu ye-bu wh-br bl-gn bl-gn bl-gn ye-gn ye-gn bl-rd bl-rd bl-ye bl-ye bu-rd bu-rd br-gn br-gn bl-ye bl-ye bu-rd bu-rd wh-rd wh-rd bl-ye bl-ye gn-rd gn-rd gn-rd 308204-01...
  • Page 177 WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Rollover sensor Side stand switch Fuel tank sensor Temperature and manifold absolute pressure sensor Lambda sensor (cylinder 1) Injection valve (cylinder 1) Combination instrument...

  • Page 178: Page 5 Of

    WIRING DIAGRAM 25.5 Page 5 of 9 wh-or wh-or ye-gn ye-gn gn-rd gn-rd wh-gr wh-gr bl-bu bl-bu wh-rd wh-rd bl-ye bl-ye wh-ye bu-pk bu-pk ye-gn wh-ye wh-ye wh-gn wh-ye wh-bu wh-bu wh-gn bl-ye ye-gn ye-gn 308205-01...
  • Page 179 WIRING DIAGRAM Components: EFI control unit Vehicle control unit Coolant temperature sensor (cylinder 1) Gear position sensor Ignition pulse generator Clutch switch Idle speed actuator Combination instrument Ignition coil (cylinder 1)

  • Page 180: Page 6 Of

    WIRING DIAGRAM 25.6 Page 6 of 9 bl-ye wh-br ye-rd bl-rd bl-rd bl-rd bl-rd bl-rd ye-rd ye-rd bl-ye ye-rd bl-ye bl-rd bl-ye bl-ye bl-ye bl-ye wh-br FG/1 FG/1 bl-ye bl-ye bl-ye 308206-01...
  • Page 181 WIRING DIAGRAM Components: Vehicle control unit Brake light switch, front Brake light switch, rear Low beam, high beam License plate lamp Combination instrument Horn Parking light Brake/tail light Emergency OFF switch, electric starter button Light switch, horn button, high beam flasher button, turn signal switch...

  • Page 182: Page 7 Of

    WIRING DIAGRAM 25.7 Page 7 of 9 bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye bu-pk bu-pk pk-br pk-br 308207-01...
  • Page 183 WIRING DIAGRAM Components: Alarm system (optional) Vehicle control unit Oil pressure sensor Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Light switch, horn button, high beam flasher button, turn signal switch...

  • Page 184: Page 8 Of

    WIRING DIAGRAM 25.8 Page 8 of 9 bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye wh-gr wh-gr bl-ye bl-ye bl-ye bl-pu wh-ye bl-ye br-rd bu-or bl-ye bl-ye bl-ye bu-or br-rd bl-ye wh-ye bl-pu bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye 308208-01...
  • Page 185 WIRING DIAGRAM Components: EFI control unit Alarm system (optional) Vehicle control unit Combination instrument...

  • Page 186: Page 9 Of

    WIRING DIAGRAM 25.9 Page 9 of 9 gn-gr rd-gr ye-gr ye-gr rd-gr ye-gr ye-gr wh-bl wh-br wh-bu wh-bu wh-br wh-bl bl-ye bl-ye bl-ye bl-ye wh-rd wh-bu wh-bu gn-gr gn-gr wh-bl wh-bl bu-pk bu-pk wh-rd wh-rd bl-bu bl-bu wh-rd wh-rd 308209-01...
  • Page 187 WIRING DIAGRAM Components: EFI control unit ABS control unit Vehicle control unit Wheel speed sensor, front Wheel speed sensor, rear Fuse Fuse ABS fuse ABS fuse Combination instrument Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • 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 corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...

  • Page 189: 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 190 AUXILIARY SUBSTANCES Lubricant (T152) Guideline – KTM recommends Bel‑Ray ® products. Supplier Bel‑Ray ® – Molylube ® Anti‑Seize Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline –...

  • Page 191: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013000 201490-10 Bleeding device Art. no.: 00029013100 201491-10 Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Clutch holder Art. no.: 51129003000 400289-01...
  • Page 192 SPECIAL TOOLS Valve spring compressor Art. no.: 59029019000 400101-01 Feeler gauge Art. no.: 59029041100 400110-01 Plastigauge measuring strips Art. no.: 60029012000 400122-01 Piston ring mounting tool Art. no.: 60029015000 400123-01 Adapter Art. no.: 61029055130 C00194-01...
  • Page 193 SPECIAL TOOLS Rear wheel stand Art. no.: 61029055400 500077-01 Front wheel stand Art. no.: 61029055500 B00756-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Adapter Art. no.: 61029955620 B00757-01...
  • Page 194 SPECIAL TOOLS Engine assembly stand Art. no.: 61229001000 200306-01 Engine blocking screw Art. no.: 61229015000 200312-01 Work stand Art. no.: 62529055000 400151-01 Floor jack attachment Art. no.: 75029055000 400184-01 Oil pressure adapter Art. no.: 75029094000 400169-01...
  • Page 195 SPECIAL TOOLS Limit plug gauge Art. no.: 77029026000 400104-01 Insert for valve spring lever Art. no.: 77029041100 303272-10 Spark plug wrench Art. no.: 77229172000 304549-10 Insert for piston pin retainer Art. no.: 77329030100 400160-01 Engine fixing arm Art. no.: 90129002050 304419-10...
  • Page 196 SPECIAL TOOLS Engine fixing arm Art. no.: 90129002060 304418-10 Mounting sleeve Art. no.: 90129005000 201612-01 Pressure screw for crankshaft Art. no.: 90129020000 304527-10 Castle nut wrench; ½" drive Art. no.: 90129021000 304430-10 Castle nut wrench; ½" drive Art. no.: 90129022000 304469-10...
  • Page 197 SPECIAL TOOLS Mounting sleeve Art. no.: 90129043000 304541-10 Case separating tool Art. no.: 90129048100 308111-01 Castle nut wrench; ½" drive Art. no.: 90129050000 305037-10 Castle nut wrench; ½" drive Art. no.: 90129050100 305037-10 Key for steering head bearing Art. no.: 90129051000 304951-10...
  • Page 198 SPECIAL TOOLS Disassembly tool, balancer shaft bearing Art. no.: 90129056000 304565-10 Puller for rotor Art. no.: 90229009000 308102-01 Hook wrench Art. no.: T106S 301085-01 Spring compressor Art. no.: T14050S 201648-10...
  • Page 199 SPECIAL TOOLS Mounting tool Art. no.: T528S 200634-10 Clamping stand Art. no.: T612S 200638-10...

  • Page 200: 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 specifi- cation.

  • Page 201: Index

    INDEX Brake discs INDEX checking ....... . . 53 Accessories ........7 Brake fluid front brake, adding .
  • Page 202 INDEX preparations ......90 Engine oil primary gear, removing ..... . 101 adding .
  • Page 203 INDEX Shift lever adjusting ....... . 147 Key number ........8 Shift speed RPM 1 Kilometers or miles adjusting .
  • Page 204 *3206167en* 3206167en 07/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

390 duke 2014 col 2013390 duke aus 2013390 duke mal 2013

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